Fabricating Bioinspired Structures with Metal Additive Manufacturing
Additive manufacturing via Direct Metal Laser Sintering (DMLS) enables fabrication of complex structures that are otherwise difficult to realize using traditional manufacturing. As a result, design and manufacture of novel 3D lattice-based designs have seen rapid growth in recent years. In particular, nature inspired designs and structures are being increasingly investigated. These structures can be fabricated to achieve a variety of functionalities and have the potential to enhance the mechanical performance of parts, including compressive, shear, and impact properties.
The Importance of Process Validation in Additive Manufacturing
Precision ADM and EOS
This paper explains the importance of achieving a process validation for AM, the process by which Precision ADM used to do so, the results of various tensile and density tests, as well as showing the complexities and hurdles that need to be overcome.
Additive Manufacturing of Customized Medical Devices
Precision ADM and the Orthopaedic Innovation Centre
The purpose of this project was to manufacture prototypes of the Surface-Guided Knee for testing on a simulator machine for kinematic validation.
The unique, patient-optimized shape of the knee lends itself to the flexibility of additive manufacturing in contrast to traditional manufacturing where deviating from set designs is penalized with high costs of production.
Conformal Cooling Mold for “Venturi Cup”
Precision ADM and Melet Plastics Inc.
A warping defect was reported in the production of a “Venturi Cup” part manufactured by Melet Plastics Inc. for use in an AGCO-Amity JV air seeder. The customer requested a reduction in the warping seen in the large rectangular section of the part.
Proposed alterations included changes in material, wall thickness and coolant temperature, as well as an optimized mold for cooling produced by Precision ADM using additive manufacturing methods. The use of the optimized mold together with a decrease in wall thickness resulted in a warpage reduction of 42%; an overall warpage reduction of 54% was achieved with all other alterations included.
Titanium Topology Optimized “TiTO™” 3D Printed Satellite Panel Support System
Precision ADM developed a “TiTO™” (Titanium Topology Optimized) Aerospace Panel Support Structure. The purpose of the project was to use topology optimization to redesign and replace a machined aluminum mount for supporting loads from a large panel and its cable management. The goal was to optimize the structural geometry to be light-weight, while maximizing its stiffness using a material that has a low coefficient of thermal expansion. Design for Additive Manufacturing (DFAM) principles were applied so the resulting design configuration could be built using Direct Metal Laser Sintering (DMLS) with minimal post-processing or machining.
R53 Engineering Motorsport Suspension Additive Redesign
Precision ADM was excited to have collaborated in an international consortium with UK-based R53 Engineering and the University of Warwick. The project involved the use of Design for Additive Manufacturing (DFAM) methodology and metal Additive Manufacturing (AM) to redesign and further improve the performance of R53 Engineering’s lightweight, state-of-the-art suspension shock absorbers for Motorsport applications.