Expanding the additive manufacturing process paradigm thorough the investigation of novel product design and process planning techniques

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Additive manufacturing (AM) methods are capable of producing complex three dimensional (3D) parts and assemblies from layering two dimensional (2D) cross sections of material successively to create the final components. AM processes are becoming more common; however, there are unique opportunities to be exploited at the product and process levels. There is little process planning control, and limited virtual simulation tools. The objectives of the proposed research program are to develop and optimize 'Product Design' and 'Process Modeling and Verification' opportunities for the Fused Deposition Modelling (FDM) and laser cladding processes. The achievable fabrication accuracies will be explored considering the product form, process parameters and build strategies using a Design of Experiments approach to understand the key control elements. It is well known that distortion occurs in casting and welding processes due to variations in heat flow - this phenomenon needs to be explored for AM processes, and solution alternatives need to be developed. For example for the FDM process, it is proposed to employ unique 3D parametric internal structures (i.e., honeycomb or grid) to optimize build time, strength and material usage, and control distortion. Design guidelines can then be developed for a given application and AM technology such as Design for Assembly for large FDM components, while considering achievable build accuracies, strength and the fabrication time. This will be complemented by developing process modeling and verification tools. There are opportunities that can be realized outside of the contemporary layered manufacturing approach, such as exploring the AM equivalent of roughing and finishing, and developing tool paths that incorporate rotary positioning (laser cladding process). Virtual reality modeling tools will be employed for developing the simulation models. This research will result in developing new and unrealized advanced design and manufacturing opportunities related to AM processes, as well as the development and commercialization of novel AM process modules within a CAM environment.