Metal AM/3D Printing processes have seen massive R&D efforts over the last few years, which have helped improve the indsutrialisation efforts of AM processes. I would be very interested to hear everyone's thoughts on what the topics are, that need to be investigated and developed over the next 5 years by those in research.
Plenty of challenges remain unsolved in laser powder bed fusion (LPBF) process. In my opinion, research in the next five years should focus more on in situ monitoring of melt pool characteristics, effective re-use of powders, development of post-treatments to reduce the surface roughness, porosity, residual stress, etc.
Thank you for your insightful reply Prof. Narayanan. I very much agree with your views.
Lots of challenges ... still many points not totally solved. Post-processing need to be enhanced to improve the surface roughness and porosity. This my affect the accuracy of the 3D model. As well as the behavior of melting of powder.
Thank you for your reponse Dr. Van Petegem, Indeed multi-material printing is a very interesting challenge for LPBF.
The development of hybrid PBF machines can be a research focus, which can have a nano-second pulsed laser for laser-based post-processing of built structures during fabrication.
Sankara Narayanan Tsn I agree, understanding melt pools and solidification is vital for advancing the field. Our group is focused on the topic through the use of in situ ultrasonics and x-rays for monitoring melt pools. Article In situ characterization of laser-generated melt pools using...
Dear Amal,
There are many challenges in the row of AM like secondary process (Heat treatment and thermo-mechanical/ thermo-chemical processing), controlling the microstructural defects by optimizing the process parameters, the effective method/process to re-use the powders and etc.
Christopher Kube Thank you for sharing your research. I find it very helpful.
P. Seenuvasaperumal Indeed, vrey much agreed. thank you for your answer.
Multi-material. Variation of properties between the surface and core.
Multi-material. Variation of properties between the surface and core.
Multi-material. Variation of properties between the surface and core.
Hesham A. Hegazi Thank you also for your input. Indeed Multi-material printing is a grand challenge. Especially for powder bed printing.
I think, in addition to multi-material and in-situ monitoring for better quality, post-processing and/or online processing is also a challenge to obtain excellent surface finish (mirror) and dimensional accuracy due to the unique microstructure and mechanical property.
Apart from the other replies, I would like to add hybrid manufacturing techniques too. I think we have a lot more to explore in this field. Proper utilization of hybrid processes can bring radical improvements. The effect of hybrid manufacturing can be assessed both in terms of process and materials point of view.
Thank you for your comments Yuchao Bai and Mustafa Rifat . I tend to agree with your remarks, there is still a lot of open topics it seems.
My opinion is that most important thing is simulation verified in-situ detection of process signature which utilizes artificial intelligence and machine learning via neural networks (deep learning). This will fasten process development, understanding of all underlying phenomena and process parameter relations, and enable faster material development.
Actually, Powder Bed Fusion (PBF) is an advanced AM technology that has matured over an extended period of research and industrial development. This technology development has enabled wide uptake of commercial applications of PBF technology, particularly for the production of high-value products that are not technically feasible with traditionally manufacturing processes.
Heidi Piili Thank you for your insight. Definitely agree with you there that the combination of AI with AM is needed and will hopefully help to quicken AM R&D.
- Printing of reflective materials,
- Utilization of Multi-materials and its process parameter optimization,
- Elimination of Shrinkages on the printed part,
- Customization of build speed, especially for SLM process,
- Commercializing the integration of the PBF process with the conventional machining process. Please take a look the below article.
Article State-of-the-art of selective laser melting process: A compr...
Eyob Messele Sefene Thank you very much for your response. Indeed some very interesting challenges!
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