Design optimisation for hybrid metal additive manufacturing for sustainable construction

Wire arc additive manufacturing (WAAM) enables the manufacturing of efficient and lightweight structural elements in which material can be utilised wherever needed in an optimised shape, in contrast to standard prismatic profiles used in construction. However, the specific energy consumption (SEC) of WAAM is higher than that of conventional...

The effect of the laser beam intensity profile in laser-based directed energy deposition: A high-fidelity thermal-fluid modeling approach

Modeling the thermal and fluid flow fields in laser-based directed energy deposition (DED-LB) is crucial for understanding process behavior and ensuring part quality. However, existing models often fail to accurately predict these fields due to simplifying assumptions, particularly regarding powder particle-induced attenuation in laser power...

Binder Jet Additive Manufacturing of Copper: Optimizing the print and post-process parameters to achieve high density copper parts

This research aimed to optimize the process parameters of small copper parts printed with binder jetting. The optimisation was distinguished by dividing the parameters in print and post-process parameters. Binder jetting is an additive manufacturing technique that combines layers of the material in powder form with a binder. After the printing...

Thermal analysis of the Wire and Arc Additive Manufacturing process using the F.E. method

In this research, a thermal analysis of the wire and arc additive manufacturing process is presented based on the F.E. method. <br/><br/>An important quality of the F.E. model that is presented in this research is to describe the temperature field that is experienced by the deposited material in the wire and arc additive manufacturing process....

Phononic crystals for suppressing crosstalk in ultrasonic flowmeters

Ultrasonic flowmeters that use transit-time ultrasonic transducers face measurement errors due to 'crosstalk,' whereby the working signal travels through the pipe wall and couplings, interfering with the signal from the fluid. Although various procedures have been proposed to solve the issue of crosstalk, they're limited to low-frequency...

Local control of microstructure and mechanical properties of high-strength steel in electric arc-based additive manufacturing

Additive manufacturing offers a significant potential for producing metallic parts with distinctly localised microstructures and mechanical properties, commonly known as functional grading. While functional grading is generally accomplished through compositional variations or in-situ thermo-mechanical treatments, variation of process...

Designing for Post-Processing: A Case Study of a 3D Printed Surgical Instrument

In this report a design is proposed for a laparoscopic gripper that can be manufactured with metal 3D printing and polished with mass finishing. The design is a continuation of the development of a laparoscopic gripper that can be 3D printed in plastic. Laparoscopic grippers 3D printed solely out of metal have not yet been presented....

Additive manufacturing of locally self-supporting compliant mechanisms: Experimental characterization and topology optimization for successful metal 3D printing

The manufacturing freedom of additive manufacturing, and design freedom of topology optimization have proven to be a fruitful combination in creating and manufacturing designs. While research into applications of metal additive manufacturing has advanced from rapid prototyping to end-use components, metal additive manufacturing of compliant...

3D Printing Metal Spare Parts On-board: The Implementation of Additive Manufacturing on-board Heerema Vessels

In this Master Thesis the potential of Additive Manufacturing on-board vessels of Heerema Marine Contractors is looked into, with the goal to design a recommendation for implementing this technology. Heerema is an offshore construction company that is intrinsically motivated to improve their sustainability. They transport, install and remove all...

Factors for metal additive manufacturing technology selection

Purpose: This paper addresses the most important factors for the selection of additive manufacturing (AM) technology as a method of production of metal parts. AM creates objects by adding material layer by layer based on 3D models. At present, interest in AM is high as it is hoped that AM contributes to the competitiveness of Western...

The set-up of an integrated working concept factory using metal additive manufacturing

In order to produce more complex parts, additive manufacturing is on the rise as a competitor for more conventional manufacturing methods. Unfortunately, additive manufacturing often produces products with a less desirable tolerance and surface roughness. Subtractive methods require special tooling and fixtures for each part design and typically...