Next Generation of Additive Manufacturing Technologies

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Additive manufacturing (AM), (i.e., 3-dimensional (3D) printing), is an emerging technology slated to change the entire manufacturing enterprise by 2030. Based on Wohler Report (2013), AM activity has increased at a compound annual growth rate (CAGR) of 32.2% over the last three years. This high CAGR has prompted swift and strong investment in AM research and development initiatives by governments across the world (e.g., $1B in USA (2012)). AM is a class of disruptive technologies that builds 3D objects by adding materials layer-by-layer. It has the potential to replace many conventional manufacturing processes as well as to enable the development of new industry practices. Despite the clear benefits of AM, several issues, such as the inability to de-powder small-sized 3D/conformal channels, have hindered full adoption of AM to medicine and engineering applications, in which structures with heterogeneous internal properties are required.***The major objective of this research program is to develop the next generation of AM technologies; to not only address the existing challenges in AM but to foster transformative research through a holistic approach and push the AM technology towards commercialization. This leading-edge research will also promote the training of HQP by enhancing their theoretical and practical engineering skills required for the multidisciplinary area of AM. The output will advance the long-term vision concerning the development of a reliable and inexpensive AM process for the fabrication of structures with a heterogeneous internal architecture.***The short-term objectives of this proposal are to: i) develop a through-process modeling framework for the novel AM process to predict optimum process parameters for desired anisotropic and/or isotropic mechanical properties of AM-made parts; ii) characterize the AM process and the associated engineered sacrificial and target materials to develop complex-shaped structures with heterogeneous porosity/density; iii) develop sensing devices for measuring contact forces during the powder particles spreading, as well as real-time closed-loop control algorithms to improve the process reliability and repeatability; iv) identify correlations of the AM and the post-sintering parameters with final mechanical and porosity properties of AM-made parts; and, v) adopt the developed AM process to lightweight complex-shaped structures for aerospace applications and anatomically-shaped implants for the biomedical sector.***This transformative research will significantly enhance Canada's competitiveness and innovation capacity in this cutting-edge area of advanced manufacturing technology research. The industrial need to adopt AM into their business plans/products is highly significant, thus the outcomes of this project have high potential for providing new leading-edge technologies for domestic and export markets.***