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The Additive Journey from Powder to Part

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Women in 3D Printing

Part of the book series: Women in Engineering and Science ((WES))

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Abstract

Additive manufacturing (AM) enables freedom of design, part complexity, and customization with minimal added cost, by fusing materials layer upon layer. AM, in general, is considered to have great potential in complementing conventional manufacturing methods. Functional parts with high strength to weight ratio generated using structural topology optimization can be eventually realized by AM. Limitations of AM parts related to surface finish and dimensional accuracy can be overcome by post-machining of critical features and surfaces in order to achieve a specific tolerance and surface quality. To minimize the trial and error efforts, accurate AM and post-machining simulations are essential for effective planning of the synergized processes. The goal of this study is to propose a process workflow which can be used as a guideline for successful production of complex parts manufactured via laser powder bed fusion (LPBF) and post-processed via CNC (computer numerical control) machining. The workflow is deployed and iterated through a case study of the manufacturing of a surgical navigation tracker, where the holistic manufacturing process involves a digital design utilizing structural topology optimization, AM part geometric distortion simulation, machining process planning, fabrication, and validation.

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Acknowledgments

The authors appreciate the funding support received from The Natural Sciences and Engineering Research Council of Canada (NSERC) – Canadian Network for Research and Innovation in Machining Technology (CANRIMT2), grant number NETGP 479639-15 and the funding contribution provided by the FedDev Ontario (Program #809104). This work was accomplished in partnership with Renishaw (Canada) Solutions Centre (Kitchener, ON, Canada), Intellijoint Surgical (Waterloo, ON, Canada), and Blue Photon (Shelby, MI, USA). In addition, the authors would like to acknowledge the help of Jerry Ratthapakdee and Karl Rautenberg at the University of Waterloo and Carl Hamann at Renishaw in helping with the LPBF prints, Robert Wagner at the University of Waterloo in helping with sample machining and cutting force measurements, and the motivation and support of the Multi-Scale Additive Manufacturing (MSAM) Group at the University of Waterloo.

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Authors and Affiliations

  1. University of Waterloo, Waterloo, ON, Canada

    Yanli Zhu, Ahmet Okyay, Mihaela Vlasea & Kaan Erkorkmaz

  2. Renishaw, Wotton-under-Edge, UK

    Mark Kirby

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  1. Yanli Zhu
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  2. Ahmet Okyay
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Correspondence to Mihaela Vlasea .

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    Stacey M DelVecchio

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Zhu, Y., Okyay, A., Vlasea, M., Erkorkmaz, K., Kirby, M. (2021). The Additive Journey from Powder to Part. In: DelVecchio, S.M. (eds) Women in 3D Printing. Women in Engineering and Science. Springer, Cham. https://doi.org/10.1007/978-3-030-70736-1_11

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  • DOI: https://doi.org/10.1007/978-3-030-70736-1_11

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