“Incremental Casting”: Support Material and Close-Loop Control of Layer Height for Direct Metal Printing with Aluminium

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As part of the previous project, water-soluble salt support structures for the droplet-based additive manufacturing of metals could be produced for the first time. In addition, the implementation of a height sensor and coupling with the printing parameters created the basis for geometry deviation compensation. The support structures were initially monolithic. However, due to the low thermal conductivity and high solidification shrinkage of salts, the height of salt support structures is limited. The use of salts only as a thin release layer minimizes the influence of the thermophysical properties of the salt on the process. In this project continuation, a process for the fabrication of the release support structures will be developed, thermally simulated and characterized. The generation of different droplet sizes allows the targeted variation of the droplet size within a component. In this way, either geometric details can be better reproduced or the printing speed can be optimized. To investigate this approach, strategies for G-code generation will be developed and suitable test specimens will be characterized.