Exploring the fabrication limits of thin-wall structures in a laser powder bed fusion process

Wu, Ziheng; Narra, Sneha P.; Rollett, Anthony D.

doi:10.1007/s00170-020-05827-4

Cited by 74 publications

(24 citation statements)

References 43 publications

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“…For example, thin-walled microsatellite fuel tanks successfully produced by laser powder bed fusion (LPBF) with wall thicknesses down to 0.75 mm [15]. Other authors suggest even more aggressive lower limits for wall thickness [16].…”

Section: Discussionmentioning

confidence: 99%

Leading-Edge Vortex Lift (LEVL) Sample Probe for Venusian Atmosphere

Isaac¹,

Jones²

2022

Aerospace

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Can a small, lightweight, free-falling sample probe be slowed enough in the Venusian atmosphere to run a 10 min microelectromechanical systems (MEMS) ion gas micro spectrometer, without adding a propulsion systems or explosives and parachutes to the probe mass? To meet this requirement a leading-edge vortex lift (LEVL) autorotating probe design (i.e., maple or sycamore seed shape) has been proposed and evaluated. It has been found that a probe with a total mass of less than 1 kg would allow prolonged flight longer than 15 min. Mathematical modelling and physical scale model testing has been performed to show that this flight time is achievable, allowing MEMS ion gas micro-spectrometer sampling of the Venusian atmosphere.

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Section: Discussionmentioning

confidence: 99%

Leading-Edge Vortex Lift (LEVL) Sample Probe for Venusian Atmosphere

Isaac¹,

Jones²

2022

Aerospace

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“…d Part deformations [73]. e Overhang tilt due to thermal distortion (highlighted in red) [74] ensure that any partially melted or highly heated particles are separated from those that will be reused [87][88][89]. & Depending on the metallic powder used in the AM processes, chemical reactions may occur between the powder and contaminants in the building environment, such as oxygen, leading to changes in the chemical composition of the powder [90].…”

Section: Limitations Of Powder-based Laser Additive Manufacturing Formentioning

confidence: 99%

Powder-based laser hybrid additive manufacturing of metals: a review

Jiménez

Bidare

Hassanin

et al. 2021

Int J Adv Manuf Technol

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Recent advances in additive manufacturing (AM) have attracted significant industrial interest. Initially, AM was mainly associated with the fabrication of prototypes, but the AM advances together with the broadening range of available materials, especially for producing metallic parts, have broaden the application areas and now the technology can be used for manufacturing functional parts, too. Especially, the AM technologies enable the creation of complex and topologically optimised geometries with internal cavities that were impossible to produce with traditional manufacturing processes. However, the tight geometrical tolerances along with the strict surface integrity requirements in aerospace, biomedical and automotive industries are not achievable in most cases with standalone AM technologies. Therefore, AM parts need extensive post-processing to ensure that their surface and dimensional requirements together with their respective mechanical properties are met. In this context, it is not surprising that the integration of AM with post-processing technologies into single and multi set-up processing solutions, commonly referred to as hybrid AM, has emerged as a very attractive proposition for industry while attracting a significant R&D interest. This paper reviews the current research and technology advances associated with the hybrid AM solutions. The special focus is on hybrid AM solutions that combine the capabilities of laser-based AM for processing powders with the necessary post-process technologies for producing metal parts with required accuracy, surface integrity and material properties. Commercially available hybrid AM systems that integrate laser-based AM with post-processing technologies are also reviewed together with their key application areas. Finally, the main challenges and open issues in broadening the industrial use of hybrid AM solutions are discussed.

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“…Wu et al [21] explored the fabrication limits of thin-wall structures from Ti-6Al-4V, AlSi10Mg and Inconel 718. The target thickness was set as between 0.1 mm and 0.5 mm, with inclined angles of 30º, 45º and 60º.…”

Section: Introductionmentioning

confidence: 99%

Effects of process parameters and geometry on dimensional accuracy and surface quality of thin strut heart valve frames manufactured by laser powder bed fusion

Zhao

Liang

Bellin³

et al. 2022

Preprint

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Laser powder bed fusion (LPBF) is one of the most popular metal additive manufacturing technologies, which has found its applications in high-value sectors such as aerospace and biomedical devices. Some recent studies on the LPBF of stents have demonstrated its feasibility in the fabrication in thin strut structures including heart valve frames, as used in transcatheter aortic valve implantation (TAVI) for the treatment of severe aortic stenosis. The state of the art method of laser cutting TAVI frame limits the scope for novel concepts which are made possible by additive manufacturing. However, the surface quality and dimensional accuracy of LPBF parts are lower than that produced by laser cutting. To start the development of new TAVI concepts, the feasibility of manufacturing thin frames by LPBF has been investigated based the SAPIEN 3 frame by Edwards Lifesciences. In this study, simplified frames with strut size from 0.3 mm to 0.5 mm have been successfully manufactured. The effects of strut size, strut angle, laser power and scan speed on the dimensional accuracy and surface quality were systemically studied. In addition, a representative SAPIEN 3 frame was manufactured and assessed with high resolution X-ray scans. Good overall dimensional accuracy and low porosity was obtained for the SAPIEN 3 frame. However, inclined struts were found to have relatively low dimensional accuracy and poor surface quality.

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Exploring the fabrication limits of thin-wall structures in a laser powder bed fusion process

Cited by 74 publications

References 43 publications

Leading-Edge Vortex Lift (LEVL) Sample Probe for Venusian Atmosphere

Leading-Edge Vortex Lift (LEVL) Sample Probe for Venusian Atmosphere

Powder-based laser hybrid additive manufacturing of metals: a review

Effects of process parameters and geometry on dimensional accuracy and surface quality of thin strut heart valve frames manufactured by laser powder bed fusion

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