Selective laser melting for improving quality characteristics of a prism shaped topology injection mould tool insert for the automotive industry

Kashouty, Mennatallah F. El; Rennie, Allan; Ghazy, Mootaz; Aziz, Ahmed Abd El

doi:10.1177/0954406221989382

Cited by 7 publications

(8 citation statements)

References 26 publications

(42 reference statements)

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“…The FBMAS recommendations conform to the recommendations indicated by the consulted experts, given the availability of the manufacturing systems. Results obtained by Kashouty et al [31] successfully demonstrate that employing SLM technology for producing tool inserts with complex surface topology proved to be an effective and efficient alternative to subtractive manufacturing. Significant benefits in terms of surface roughness, dimensional accuracy, and product functionality were achieved through the use of SLM technology for the fabricated tool inserts in comparison to their CNC counterparts.…”

Section: Core Insert Features Evaluation Using Fbmasmentioning

confidence: 99%

A Novel Feature-Based Manufacturability Assessment System for Evaluating Selective Laser Melting and Subtractive Manufacturing Injection Moulding Tool Inserts

Kashouty

Rennie

Ghazy

2023

Designs

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Challenges caused by design complexities during the design stages of a product must be coordinated and overcome by the selection of a suitable manufacturing approach. Additive manufacturing (AM) is capable of fabricating complex shapes, yet there are limiting aspects to surface integrity, dimensional accuracy, and, in some instances, design restrictions. Therefore, the goal is essentially to establish the complex areas of a tool during the design stage to achieve the desired quality levels for the corresponding injection moulding tool insert. When adopting a manufacturing approach, it is essential to acknowledge limitations and restrictions. This paper presents the development of a feature-based manufacturability assessment system (FBMAS) to demonstrate the feasibility of integrating selective laser melting (SLM), a metal-based AM technology, with subtractive manufacturing for any given part. The areas on the tool inserts that hold the most geometrical complexities to manufacture are focused on the FBMAS and the design features that are critical for the FBMAS are defined. Furthermore, the structural approach used for developing the FBMAS graphical user interface is defined while explaining how it can be operated effectively and in a user-friendly approach. The systematic approach established is successful in capturing the benefits of SLM and subtractive methods of manufacturing, whilst defining design limitations of each manufacturing method. Finally, the FBMAS developed was validated and verified against the criteria set by experts in the field, and the system’s logic was proven to be accurate when tested. The decision recommendations proved to correlate with the determined recommendations of the field experts in evaluating the feature manufacturability of the tool inserts.

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Section: Core Insert Features Evaluation Using Fbmasmentioning

confidence: 99%

A Novel Feature-Based Manufacturability Assessment System for Evaluating Selective Laser Melting and Subtractive Manufacturing Injection Moulding Tool Inserts

Kashouty

Rennie

Ghazy

2023

Designs

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“…In 2018, BMW produced 3D-printed window guides, and BMW has already used 3D printing technology to make 1 million car parts. The use of SLM in the automobile industry will increasingly advance with ongoing technological advancement [32][33][34].Figure 2 shows the small engine parts produced by Anhui Tuobao Additive Manufacturing Technology Co., Ltd. using SLM.…”

Section: Slm Application In Automobile Industrymentioning

confidence: 99%

Research and Development Status of Selective Laser melting (SLM)

Li¹,

Li²,

Huang³

et al. 2023

Preprint

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With the development of industrialization, traditional manufacturing technologies are no longer able to meet the production needs of modern society. Additive manufacturing has successfully solved the problems existing in traditional manufacturing technology. Selective laser melting (SLM) is a powder bed melting technology that produces metal parts by selectively melting metal powders on a platform using a laser beam. It is widely used in additive manufacturing. This article introduces the characteristics and current development status of SLM technology, summarizes the main application fields and common defects of SLM, and finally explores and prospects the future development trend of SLM.

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“…Metal-based AM technologies can produce geometries that traditional methods cannot produce, thanks to the possibility of different material structures, internal channels for heating or cooling, and embedded sensors present in parts produced in a single step [50,[89][90][91]. Conversely, surface finish and dimensional accuracy are still two major limitations of AM in IM.…”

Section: Indirect Am Processesmentioning

confidence: 99%

A Review of Automotive Spare-Part Reconstruction Based on Additive Manufacturing

Dalpadulo

Petruccioli

Gherardini

et al. 2022

JMMP

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In the Industry 4.0 scenario, additive manufacturing (AM) technologies play a fundamental role in the automotive field, even in more traditional sectors such as the restoration of vintage cars. Car manufacturers and restorers benefit from a digital production workflow to reproduce spare parts that are no longer available on the market, starting with original components, even if they are damaged. This review focuses on this market niche that, due to its growing importance in terms of applications and related industries, can be a significant demonstrator of future trends in the automotive supply chain. Through selected case studies and industrial applications, this study analyses the implications of AM from multiple perspectives. Firstly, various types of AM processes are used, although some are predominant due to their cost-effectiveness and, therefore, their better accessibility and wide diffusion. In some applications, AM is used as an intermediate process to develop production equipment (so-called rapid tooling), with further implications in the digitalisation of conventional primary technologies and the entire production process. Secondly, the additive process allows for on-demand, one-off, or small-batch production. Finally, the ever-growing variety of spare parts introduces new problems and challenges, generating constant opportunities to improve the finish and performance of parts, as well as the types of processes and materials, sometimes directly involving AM solution providers.

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Selective laser melting for improving quality characteristics of a prism shaped topology injection mould tool insert for the automotive industry

Cited by 7 publications

References 26 publications

A Novel Feature-Based Manufacturability Assessment System for Evaluating Selective Laser Melting and Subtractive Manufacturing Injection Moulding Tool Inserts

A Novel Feature-Based Manufacturability Assessment System for Evaluating Selective Laser Melting and Subtractive Manufacturing Injection Moulding Tool Inserts

Research and Development Status of Selective Laser melting (SLM)

A Review of Automotive Spare-Part Reconstruction Based on Additive Manufacturing

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