Evolution of Design Guidelines for Additive Manufacturing - Highlighting Achievements and Open Issues by Revisiting an Early SLM Aircraft Bracket

Klahn, Christoph; Omidvarkarjan, Daniel; Meboldt, Mirko

doi:10.1007/978-3-319-66866-6_1

Cited by 12 publications

(5 citation statements)

References 16 publications

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“…For example, parallel clamping jaws must be produced as a negative shape, which is cost-intensive for customized parts at the mass scale [12]. Producing integrated parallel clamping interfaces in the LPBF process restricts the design freedom and increases the processing time [13]. Clamping jaws limit milling tools' access and require manual processes, which are costintensive and unsuitable for automation [14].…”

Section: Introductionmentioning

confidence: 99%

Design and validation of a sheet metal clamping system for additive manufacturing and post-processing

Ferchow

Bühler

Schlüssel³

et al. 2022

Int J Adv Manuf Technol

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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.

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Section: Introductionmentioning

confidence: 99%

Design and validation of a sheet metal clamping system for additive manufacturing and post-processing

Ferchow

Bühler

Schlüssel³

et al. 2022

Int J Adv Manuf Technol

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“…The manufacturing of inclined structures is one of the limiting criterions in the SLM process. To allow sufficient heat dissipation, inclinations have to be built with additional support structures to avoid thermal deformation [ 14 , 42 , 43 , 44 ]. Depending on material and process parameters, the minimum inclination angle for the manufacturing of unsupported structures is defined for SLM in several studies between 20

[ 25 , 45 , 46 ] and 45

[ 15 , 24 ].…”

Section: Results and Discussionmentioning

confidence: 99%

Design Rules for Hybrid Additive Manufacturing Combining Selective Laser Melting and Micromilling

et al. 2021

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We report on a comprehensive study to evaluate fundamental properties of a hybrid manufacturing approach, combining selective laser melting and high speed milling, and to characterize typical geometrical features and conclude on a catalogue of design rules. As for any additive manufacturing approach, the understanding of the machine properties and the process behaviour as well as such a selection guide is of upmost importance to foster the implementation of new machining concepts and support design engineers. Geometrical accuracy between digitally designed and physically realized parts made of maraging steel and dimensional limits are analyzed by stripe line projection. In particular, we identify design rules for numerous basic geometric elements like walls, cylinders, angles, inclinations, overhangs, notches, inner and outer radii of spheres, chamfers in build direction, and holes of different shape, respectively, as being manufactured by the hybrid approach and compare them to sole selective laser melting. While the cutting tool defines the manufacturability of, e.g., edges and corners, the milling itself improves the surface roughness to Ra < 2μm. Thus, the given advantages of this hybrid process, e.g., space-resolved and custom-designed roughness and the superior geometrical accuracy are evaluated. Finally, we exemplify the potential of this particular promising hybrid approach by demonstrating an injection mold with a conformal cooling for a charge socket for an electro mobile.

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“…A study of the cycle was performed on the printed segment together at the earliest reference stage, both to think about the dimensional deviations between it and the CAD component and to analyze the real segment using the Finite Element Method (FEM). Klahn, Omidvarkarjan and Meboldt et al [9] showed the weight-saving capability of Selective Laser Melting (SLM) and fill it as a technology demonstrator featuring the potential of this youthful creative technology. What really had any effect are strategies for composing the work process and overcoming limitations, e.g.…”

Section: The Methods Of Ammentioning

confidence: 99%

A Comprehensive Literature Research of the Additively Manufactured Airborne Parts

Saraçyakupoğlu

2022

Journal of Aviation Research

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Evolution of Design Guidelines for Additive Manufacturing - Highlighting Achievements and Open Issues by Revisiting an Early SLM Aircraft Bracket

Cited by 12 publications

References 16 publications

Design and validation of a sheet metal clamping system for additive manufacturing and post-processing

Design and validation of a sheet metal clamping system for additive manufacturing and post-processing

Design Rules for Hybrid Additive Manufacturing Combining Selective Laser Melting and Micromilling

A Comprehensive Literature Research of the Additively Manufactured Airborne Parts

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