A review on design and removal of support structures in metal additive manufacturing

Zhang, Jiong; Cao, Qiqiang; Lu, Wen Feng

doi:10.1016/j.matpr.2022.09.277

Cited by 9 publications

(2 citation statements)

References 29 publications

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“…This specific CAD has been named the WAAM-process-adapted CAD. Moreover, to avoid problems related to small failures in the printing procedure [71][72][73], such as a lack of material or occasional welding errors, every surface was designed with this over-thickness during the WAAM-process-adapted CAD. This over-thickness was initially set at 10 mm.…”

Section: Methodsmentioning

confidence: 99%

Analysis of Energy and Material Consumption for the Manufacturing of an Aeronautical Tooling: An Experimental Comparison between Pure Machining and Big Area Additive Manufacturing

Marqués,

Dieste,

Monzón

et al. 2024

Materials

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Additive manufacturing (AM) has been fully incorporated into both the academic and the industrial world. This technology has been shown to lower costs and environmental impacts. Moreover, AM-based technologies, such as wire arc additive manufacturing (WAAM), have been proven suitable for the manufacturing of large products with significant mechanical requirements. This study examines the manufacture of two aeronautical toolings: first, using conventional techniques, and second, using a big area additive manufacturing (BAAM) process, specifically WAAM technology, followed by second-stage hybrid machining. Both toolings can be considered interchangeable in terms of design and performance. Energy and material consumption were analysed and compared throughout both tooling procedures. The results show the important optimisation of both procedures in manufacturing WAAM tooling, encompassing the additive process and second-stage hybrid machining. Nevertheless, the time required for WAAM tooling manufacturing increased significantly compared to conventional manufacturing tooling. Moreover, based on metrology data from the AM process, a theoretical study was conducted to assess different design optimisations for WAAM tooling manufacturing and determine their influence on material and energy consumption. These theoretical results improve those already obtained regarding energy and raw material savings.

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Section: Methodsmentioning

confidence: 99%

Analysis of Energy and Material Consumption for the Manufacturing of an Aeronautical Tooling: An Experimental Comparison between Pure Machining and Big Area Additive Manufacturing

Marqués,

Dieste,

Monzón

et al. 2024

Materials

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show abstract

“…Recently, considerable research has been conducted on the design of support structures for AM technology. (Zhang et al 2022) have characterized the limitations of metallic AM in the usage of support structure utilization and proposed several methods to eliminate the support structure. (Cheng et al 2019) proposed a method to design the support structure by optimizing the construction direction and the honeycomb structure.…”

Section: Introductionmentioning

confidence: 99%

Stress and temperature constrained thermoelastic topology optimization of support structures for additive manufacturing

Zhou,

Zhao,

Jiang

2024

Preprint

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This paper presents a thermoelastic topology optimization formulation for the design of support structures in layer-by-layer printed additive manufacturing. The formulation is written in the form of structural compliance minimization with two competing constraint functions, one related to mechanical performance (stress) considering mechanical stress and thermal stress and one related to thermal performance (temperature). The optimization problem is solved by applying the p-norm function to handle global stress constraints and overall temperature constraints, separately. The sensitivity information of the objective function and constraints is derived using the adjoint variable method. The design variables are updated using the Method of Moving Asymptotes (MMA). We present several examples that explore the ability of the formulation to obtain optimized support structures for additive manufacturing under different volume constraints, various performance constraints and print orientations, which addresses the issues of mechanical and thermal stress concentration when considering thermoelastic coupled effect, thus validating the effectiveness of the proposed method.

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Mechanical property estimation for additive manufacturing parts with supports

Günaydın,

Gunpinar

2023

Int J Adv Manuf Technol

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A review on design and removal of support structures in metal additive manufacturing

Cited by 9 publications

References 29 publications

Analysis of Energy and Material Consumption for the Manufacturing of an Aeronautical Tooling: An Experimental Comparison between Pure Machining and Big Area Additive Manufacturing

Analysis of Energy and Material Consumption for the Manufacturing of an Aeronautical Tooling: An Experimental Comparison between Pure Machining and Big Area Additive Manufacturing

Stress and temperature constrained thermoelastic topology optimization of support structures for additive manufacturing

Mechanical property estimation for additive manufacturing parts with supports

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