This paper provides an overview on the main additive manufacturing/3D printing technologies suitable for many satellite applications and, in particular, radio-frequency components. In fact, nowadays they have become capable of producing complex net-shaped or nearly parts materials that can be directly used as functional parts, including polymers, metals, ceramics, and composites. These represent solution low-volume, high-value, highly products.

In this paper, a characterization of an AlSiMg alloy processed by direct metal laser sintering (DMLS) is presented, from the analysis starting powders, in terms size, morphology and chemical composition, through to evaluation mechanical microstructural properties specimens built along different orientations parallel perpendicular powder deposition plane. With respect similar aluminum as-fabricated, higher yield strength about 40% due very fine microstructure, closely related mechanisms...

Purpose The purpose of this paper is to highlight how rapid manufacturing (RM) plastic parts combined with part redesign could have positive repercussion on cost saving. Design/methodology/approach Comparison between two different technologies for production, the traditional injection molding (IM) and emergent RM, done consideration both geometric possibilities RM economic aspect. From an extended literature review, guidelines model are identified then applied a component selected its shape...

Purpose – The aim of this research is to reach a deep understanding on the effect process parameters Direct Metal Laser Sintering (DMLS) macroscopic properties (hardness and density) AlSi10Mg parts resulting microstructure. Design/methodology/approach A full factorial design experiment (DOE) was applied determine most significant parameter influencing manufactured by DMLS process. analysis aims define optimum deduce window that provides better parts. Optical microscopy observations are...

Residual stresses (RS) of great magnitude are usually present in parts produced by Laser Powder Bed Fusion (PBF-LB), mainly owing to the extreme temperature gradients and high cooling rates involved process. Those “hidden” can be detrimental a part’s mechanical properties fatigue life; therefore, it is crucial know their orientation. The hole-drilling strain-gage method was used determine RS direction-depth profiles. Cuboid specimens as-built state, after standard solution annealing ageing...

During the Selective Laser Melting (SLM) process, scanned layers are subjected to rapid thermal cycles. Steep temperature gradients generate residual stresses. Residual stresses can be detrimental proper functioning and structural integrity of built parts. In this paper, semi-destructive hole-drilling method has been used measure on AISi10Mg parts after building, stress relieving shot-peening, respectively. The outcomes have shown presence, as-built components, high tensile that usual...

Laser powder bed fusion (L-PBF) is an additive manufacturing (AM) process that allows to build full dense metal complex part. However, despite the obvious benefits of L-PBF process, it affected by specific technological drawbacks and suffers from issues regarding design support tools. In order fully exploit advantages L-PBF, necessary know constraints, such as material availability need minimise structures. this paper, integrated procedure involves topology optimisation, for laser rules...

Among the various Additive Manufacturing (AM) technologies available for metal part production, powder bed processes are most promising industrial mass production. However, one obstacle to widespread adoption of AM is effect residual stress state on integrity and lifetime parts. The influenced a great extent by geometry orientation part, such conditions as distance regions from building platform or geometrical constraints may change values distribution. This work describes an experimental...

Residual stresses can be detrimental to the proper functioning and structural integrity of built parts. During selective laser melting (SLM) process, scanned layers are subjected rapid thermal cycles. Steep temperature gradients generate residual stresses. In this paper, semi-destructive hole-drilling method has been used measure on AISi10Mg parts fabricated by means an SLM process. The evolution profile samples is illustrated in function process phase (as-built, after treatment,...

The specific energy consumption of Additive Manufacturing (AM) unit processes for the production metal parts could be much higher than that more traditional manufacturing routes, such as machining. However, AM, due to its intrinsic process peculiarities, including flexible realization (almost) any kind complex shape, has a great potential improving material use efficiency, with positive environmental impact benefits from product and disposal at end first life. Aim this paper is assess role...

Additive manufacturing allows for a great degree of design freedom and is rapidly becoming mainstream process. However, as in all processes, it has its limitations specificities. Equipping engineers with this knowledge higher optimization, extracting the most out technology. Therefore, specific part was devised created via L-PBF (Laser Powder Bed Fusion) using AlSi10Mg powder. Certain parameters were varied to identify influence on material density, hardness, roughness, residual stress...

Abstract Since the advent of Industry 4.0, manufacturing sector has had to face new challenges, which require development skills and innovative tools. This scenario includes production processes such as additive (AM), a technology capable producing component layer-by-layer directly from 3D model without needing specific tools during building phase. Generative design (GD) may represent an opportunity maximise potential AM techniques. GD is based on parametric computer-aided (CAD) generating...

Metal components produced by Additive Manufacturing (AM) technologies usually exhibit a rough surface, that in certain applications can result detrimental for the part's functionality. Thus, it is of great interest to study finishing processes be applied surfaces, both external and internal, AM components. The aim this work evaluation capabilities vibro-finishing process treatment samples Laser-Powder Bed Fusion (L-PBF) from AlSi10Mg powders. In research, abrasive media identified, surface...

Laser Powder Directed Energy Deposition (LP-DED) is a very powerful Additive Manufacturing process for different applications, such as repair operations and the production of functionally graded material. However, application still limited, one main reasons related to lack knowledge mechanisms. Since mechanisms involved in process, which are mutually each other, directly influence properties produced part, their crucial. This paper presents review LP-DED relationship between input parameters...

Additive manufacturing (AM) technologies for metallic materials allow the of high-performance components optimised in weight, geometry, and mechanical properties. However, several post-processing operations are needed after production, including removing parts from build platform. This operation is essential must be performed rapidly, precisely, with a good surface finishing. work presents an experimental investigation wire electric discharge machining (W-EDM) process Ti6Al4V specimens...