Design And Validation of A Sheet Metal Clamping System For Additive Manufacturing and Post-Processing

Abstract

Automated clamping for post-processing of mass-customized parts is a challenging step in the laser powder bed fusion (LPBF) process chain. In this study, a novel modular sheet metal clamping system was developed that uses disposable sheet metal profiles as a universal interface for the LPBF, robotic handling, and milling processes. Based on a fundamental investigation of hybrid additive manufacturing, the sheet metal clamping system was designed to use the same interface for the LPBF and milling processes. Subsequent an end-to-end validation was performed for the entire process chain. The concept of the sheet metal clamping system gives milling tools access to a part on five to six sides. Further, the part can be accessed from the top and bottom sides, and simplifying the removal of LPBF supports. No clamping forces are induced in the LPBF part, which is especially important for filigree structures. The sheet metal clamping system’s underlying concept could be adapted to automating the LPBF process chain for applications such as prosthetic dentistry.

A review on additive manufacturing for aerospace application

“…Producing or replacing parts using additive manufacturing techniques requires proficient design skills with appropriate training [126]. As there is a lag in supervision and employing AM in industry, add-on training in education perhaps will support [127]. The education aspect can be enhanced by implementing the additive manufacturing training program in the curriculum.…”

Overview of Identified Challenges in the Development Process of Superconducting Accelerator Magnets

“…The available literature describes technical challenges in the general magnet development process extensively. Many academic papers cover new technologies and integration challenges, such as [10][11][12][13]. Identified problems and solutions in these sources are generally very detailed and technical.…”