Among metal additive manufacturing processes, Selective Laser Melting (SLM) belongs to the powder bed fusion category. Also known as Direct Metal Laser Melting (DMLM), the technique is named after its fundamental mechanism. The process relies on a fine laser beam that is scanned across successive layers of a powder bed to selectively melt intricate tracks. The final components arise from solidification of the melted powder. When compared to other additive manufacturing technologies, this ability to produce high resolution features is one of the reasons why SLM tends to get selected to produce complex components with delicate features.
How do you combine design guiderules for SLM and topology optimisation? How do you prioritise the design optimisation tasks while minimising the design iterations?
Industrial designers do not yet have a clear framework to review, redesign, and optimise existing designs in order to take full advantage of the benefits that SLM can offer.
In this post, we present the methodology used to redesign an aluminium bracket for SLM in order to save weight while maintaining performance. The key objective is to take into account the manufacturing constraints, user’s requirements and take advantage of technology’s design freedom.
Effect of particles size distribution and packing density on the formation of balling defects during SLM of In718
Balling is a defect that can occur when the molten pool created during selective laser melting (SLM=L-PBF) becomes discontinuous and breaks into separated islands. In this post, we report and discuss how the powder particle arrangement impact the bead geometry and formation of balling defects during SLM.
A356 aluminium alloy (AlSi7Mg0.3) is widely used for gravity casting. Its good ductility, strength and corrosion resistance properties make it a compelling material for components requiring high reliability. Examples of parts traditionally built using A356 include engine parts, hydraulic components, brackets, housing covers in automotive, aerospace, and machinery industries [1, 2].
In this post we present the superior mechanical properties of A356 components showing 99.8% relative density  and built on the EOSINT M280.
Nickel-based superalloys have great applications in the fabrication of turbine blades, jet engines, and other high-value metal components found in marine applications, industrial or nuclear reactors. Using additive manufacturing technology to build these components can offer significant benefits. However, the laser processability of these alloys shows they are prone to cracking.
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