Additive Manufacturing

Additive Manufacturing: Ensuring High Quality of 3D-Printed Parts using Computational Approaches

Additive Manufacturing (AM) technologies have proven to be very promising due to their ability in fabricating parts in complex shapes with tailored physical properties. This enables many new possibilities to design and manufacture optimal patient-specific implants or new products for aerospace and automotive industries which increase safety together with a reduction of pollutant emissions.

However, the uncertainty in the quality of the final printed parts mainly hinders the wide industrialization of AM technologies. More than 100 parameters affect the quality making it difficult or mostly nearly impossible to find the best setup to fabricate the product with the desired properties.

Computational approaches are ideal for giving insights into the physical mechanism of the whole printing process. The influence of each process parameter on the quality of the final part can be individually analyzed in detail. If high fidelity computational models of this process are available, simulation software can be integrated into AM printers making a new generation of Advanced Additive Manufacturing possible.

To fully understand the physical mechanism with the help of simulation tools the fusion of material has to be accurately modeled. This process involves large deformations and intrinsic discontinuities. Hence meshfree methods are ideal solution schemes for the simulation of AM processes.

Additive Manufacturing