Continuation of Characterization and Design of Additively Manufactured Components for Materials Integrity

Rapid prototyping, or 3D printing, has inspired the imagination of the general public, from simple build-it-yourself “hobby” machines using polymer-based binder material with inkjet functionality, to portable printers that can fashion components in zero gravity on the International Space Station. The functionality is user-friendly, in that printed material is dropped onto a substrate in viscous plastic form, which solidifies to take on the designed shape. The resulting piece is a plastic prototype that may be used as-is, for some applications, or as scaled models to assist the product development process. This work focuses on 3D metal printing, specifically, direct metal laser sintering (DMLS), to build three-dimensional, complex parts using metallic powders. We integrate materials science, design of experiments, and engineering design for the purpose of manufacturing components with complex geometries and lightweight, high-strength metallic-alloy properties for aircraft applications. By investigating how process parameters affect the properties of materials, we expect to reduce run-to-run variations in the DMLS process, reduce production and post-production time and costs, and contribute to innovation in using an additive approach to the engineering design of complex components.

Faculty Supervisor:

Amy Hsiao;Grant McSorley

Student:

Lucas Gabriel Gallant

Partner:

MDS Coatings

Discipline:

Engineering

Sector:

Manufacturing

University:

University of Prince Edward Island