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In metals additive manufacturing (AM), materials and components are concurrently made in a single process as layers of metal are fabricated on top of each other in the near-final topology required for the end-use product. Consequently, tens…
Additive manufacturing (AM; 3D Printing), a process which creates a part layer-by-layer, has the potential to improve upon conventional lightweight mirror manufacturing techniques, including subtractive (milling), formative (casting) and…
Additive manufacturing is a process that has facilitated the cost effective production of complicated designs. Objects fabricated via additive manufacturing technologies often suffer from dimensional accuracy issues and other part specific…
Uniform powder spreading is a requisite for creating consistent, high-quality components via powder bed additive manufacturing (AM), wherein layer density and uniformity are complex functions of powder characteristics, spreading kinematics,…
In additive manufacturing (AM), particularly for laser-based metal AM, process optimization is crucial to the quality of products and the efficiency of production. The identification of optimal process parameters out of a vast parameter…
During powder production, the pre-alloyed powder composition often deviates from the target composition leading to undesirable properties of additive manufacturing (AM) components. Therefore, we developed a method to perform high-throughput…
The quality of powder layers, specifically their packing density and surface uniformity, is a critical factor influencing the quality of components produced by powder bed metal additive manufacturing (AM) processes, including selective…
Configuring the parameters of additive manufacturing processes for metal alloys is a challenging problem due to complex relationships between input parameters (e.g., laser power, scan speed) and quality of printed outputs. The standard…
Modeling plays a critical role in additive manufacturing (AM), enabling a deeper understanding of underlying processes. Parametric solutions for such models are of great importance, enabling the optimization of production processes and…
A path to lowering the economic barrier associated with the high cost of metal additively manufactured components is to reduce the waste via powder reuse (powder cycled back into the process) and recycling (powder chemically, physically, or…
In context of laser powder bed fusion (L-PBF), it is known that the properties of the final fabricated product highly depend on the temperature distribution and its gradient over the manufacturing plate. In this paper, we propose a novel…
Rapid cooling rates and stochastic interactions between the heat source and feedstock in additive manufacturing (AM) result in strong anisotropy and process-induced defects deteriorating the tensile ductility and fatigue resistance of…
In our study, molecular dynamics (MD) simulations of laser powder bed fusion (LPBF) have been conducted on equimolar FeNiCr medium entropy alloy (MEA) powders. With the development of newer LPBF technologies capable of printing at the…
Thin-walled structures capable of large, reversible deformation are key to multistable structures, origami, kirigami, and soft robotics. However, conventional fabrication techniques, including 3D printing, casting, and laser cutting, suffer…
In a powder bed fusion additive manufacturing (AM) process, the balling effect has a significant impact on the surface quality of the printing parts. Surface wetting helps the bonding between powder and substrate and the inter-particle…
To control part quality, it is critical to analyze pore generation mechanisms, laying theoretical foundation for future porosity control. Current porosity analysis models use machine setting parameters, such as laser angle and part pose.…
Numerical simulations have revolutionized the industrial design process by reducing prototyping costs, design iterations, and enabling product engineers to explore the design space more efficiently. However, the growing scale of simulations…
Design For Manufacturing (DFM) approaches aim to integrate manufacturability aspects during the design stage. Most of DFM approaches usually consider only one manufacturing process, but products competitiveness may be improved by designing…
While multiple sensors are used for real-time monitoring in additive manufacturing, not all provide practical or reliable process insights. For example, high-speed X-ray imaging offers valuable spatial information about subsurface melt pool…
Thermal multi-phase flow simulations are indispensable to understanding the multi-scale and multi-physics phenomena in metal additive manufacturing (AM) processes, yet accurate and robust predictions remain challenging. This book chapter…