Additive Manufacturing (AM) offers many potential benefits over traditional manufacturing techniques. It enables the generation of complex geometries and lattice structures to make lighter components, can improve thermal performance through more flexible cooling design, avoids the need for expensive tooling for short production runs and may make mass customisation a reality as customers seek more personalised products.
AM applications can been found in a wide range of industries, including Aerospace, Defence, Automotive, Sports and Medical.
However, there are still many challenges to overcome before AM can be ‘fully industrialised’. The weight and performance benefits of components redesigned for AM are proven, yet equipment and production costs can still be noncompetitive compared to other manufacturing technologies. Furthermore, product distortion during AM, variations in material properties and surface finish issues mean that assuring quality may be difficult.
Due to the inherent digital nature of AM, simulation offers vast potential to ensure the benefits of AM can be fully exploited within product design while avoiding failures experienced during the build process. Consequently, it is vital that a simulation workflow is established, providing design, research and manufacturing engineers involved in AM with the tools and guidelines to maximise its true potential.
This NAFEMS seminar brought together leading experts in AM to discuss current challenges, the latest simulation techniques and how they are being deployed by leading companies.
Risk and Opportunity in Additive Manufacturing Design
Andrew Triantaphyllou, The Manufacturing Technology Centre
Considerations for New System Design using Additive Manufacturing as a Technology Enabler
Adam Arnold, Additive Design Consultancy
Advances in Validating Powder Bed Fusion Simulations: From Distortion to Metallurgy
Tyler London, TWI
The Road to Production: The role of Multidisciplinary Simulation on AM Parts
Dimitris Katsanis, METRON Advanced Equipment Ltd.
Benefits from Simulation in Additive Manufacturing
Anas Yaghi, The Manufacturing Technology Centre
Towards Integration of Material, Powder, Process and Part in Design for
Anssi Laukkanen, VTT Technical Research Centre of Finland
A Complete Design Process for Complex Additively-Manufactured Titanium Part, Based on Component Fatigue Life Optimisation, Manufacturing Simulation and Physical Test Correlation
Steffan Evans, Evotech CAE Ltd.
Cone Filter Optimisation and Performance Enhancement via Simulations for Fabrication with Additive Manufacturing
Louise Geekie , Croft Additive Manufacturing