Industrialization of Additive Manufacturing

123 Pages·2017·3.13 MB·English

Industrialization of Additive
Manufacturing
Development of an Additive Manufacturing
Design Guide for Metal Laser Powder Bed
Fusion
Master’s thesis in Product Development
JOHAN SÖNEGÅRD
MARIA WARHOLM
Department of Product and Production Development
CHALMERS UNIVERSITY OF TECHNOLOGY
Gothenburg, Sweden 2017
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Industrialization of Additive Manufacturing
Development of Additive Manufacturing Design Guide for Metal Laser Powder Bed Fusion
JOHAN SÖNEGÅRD
MARIA WARHOLM
Department of Product and Production Development
CHALMERS UNIVERSITY OF TECHNOLOGY
Gothenburg, Sweden 2017
iii
Industrialization of Additive Manufacturing
Development of Additive Manufacturing Design Guide for Metal Laser Powder Bed Fusion
JOHAN SÖNEGÅRD
MARIA WARHOLM
© JOHAN SÖNEGÅRD AND MARIA WARHOLM, 2017
Examiner: Lars Lindkvist Associate Professor, Division Product development, Department of
Product and Production Development, Chalmers University of Technology
Supervisor: Hans Sjöberg Research Engineer, Division Production Systems, Department of
Product and Production Development, Chalmers University of Technology
Department of Product and Production Development
Chalmers University of Technology
Gothenburg, Sweden 2017
SE-412 96 Göteborg
Sweden
Telephone + 46 (0)31-772 1000
A photo of four aluminum benchmark models can be seen on the front cover. These were
manufactured in an EOS M290 machine using the standard machine parameters. More about
the models can be read in Chapter 6 Benchmark model.
Chalmers Reproservice
Gothenburg, Sweden 2017
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Industrialization of Additive Manufacturing
Development of Additive Manufacturing Design Guide for Metal Laser Powder Bed Fusion
JOHAN SÖNEGÅRD
MARIA WARHOLM
Department of Product and Production Development
Chalmers University of Technology
ABSTRACT
Additive manufacturing (AM) is a relatively new manufacturing method that adds material
instead of subtracting it as the traditional manufacturing methods do. The AM technology
started with melting plastic and creating structures in three dimensions. However, this
master’s thesis focuses on the AM technology where metals can be used as material and more
specifically the laser powder bed fusion process. More and more companies have found an
interest in the possibilities AM provides but there are also limitations that are important to be
aware of to fully utilize the potential of the technology.
The thesis was conducted with Saab AB Surveillance and the aim was to find and gather as
much knowledge as possible regarding design rules for the laser powder bed AM method with
a focus on aluminum. This was done through literature research and interviews that showed
there are many general guidelines that apply to all metals. The result was collected in a
document with the purpose for designers with limited or no previous knowledge about design
for AM to read it and then be able to understand enough about the process to start designing
self-supporting parts. To verify the design rules, a benchmark model was designed. The
model was manufactured in an EOS M290 machine in aluminum and the result showed that
more extreme features can be built than the theory indicated. Based on the results the model
was redesigned and a new version was manufactured.
Keywords: Additive manufacturing, 3D-printing, design guidelines, Product Development,
DfAM, design for additive manufacturing, powder bed fusion
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ACKNOWLEDGEMENTS
We would like to thank everybody that has been helping us with the thesis. Special thanks to
our supervisor at Chalmers Hans Sjöberg, Research Engineer, Division Production Systems,
Department of Product and Production Development, Chalmers University of Technology.
Thanks to our examiner Lars Lindkvist, Associate Professor, Division Product development,
Department of Product and Production Development, Chalmers University of Technology.
Many people at Saab AB Surveillance have helped us achieve the final result, especially
Pamelina Olsson who has been our supervisor at Saab AB Surveillance. Martin Blennius for
sharing great ideas and his knowledge about AM, Christer Bjurek for his support and
everybody who gave feedback on different parts of the report to make it even better.
Thanks to Karolina Johansson and Torbjörn Holmstedt at Lasertech LSH AB who helped us
understanding the printing process better and for helping us with feedback on the benchmark
model.
The last thanks goes out to everyone we interviewed for taking their time answering our
questions and made this thesis possible.
Johan Sönegård
Maria Warholm
Gothenburg, June 2017
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Table of Contents
1 Introduction .....................................................................................................................1
1.1 Background ..............................................................................................................2
1.2 Purpose ....................................................................................................................3
1.3 Delimitations ............................................................................................................3
1.4 Problem analysis and research questions ...................................................................4
1.5 Ethical, legislative and environmental aspects ..........................................................4
2 Method ............................................................................................................................7
2.1 Literature study ........................................................................................................7
2.2 Interviews.................................................................................................................8
2.3 Benchmark model ....................................................................................................9
2.4 Feedback ..................................................................................................................9
3 Frame of references ....................................................................................................... 11
3.1 Additive manufacturing .......................................................................................... 11
3.2 Evaluation and Transformation for Additive Manufacturing (ETAM) ..................... 15
4 Interviews...................................................................................................................... 17
4.1 Designers ............................................................................................................... 17
4.2 The manufacturers .................................................................................................. 20
5 A Designer’s Handbook for Metal Additive Manufacturing ........................................... 23
5.1 What is additive manufacturing .............................................................................. 23
5.2 What to know before designing .............................................................................. 24
5.3 Design rules and guidelines .................................................................................... 25
5.4 Pre- and post-processing ......................................................................................... 29
5.5 Examples ................................................................................................................ 29
5.6 Future work and notes ............................................................................................ 29
5.7 Recommended reading ........................................................................................... 29
6 Benchmark model ......................................................................................................... 31
6.1 Features .................................................................................................................. 31
6.2 The process ............................................................................................................ 31
6.3 First print ............................................................................................................... 32
6.4 Final version ........................................................................................................... 37
6.5 Second print ........................................................................................................... 38
7 Discussion ..................................................................................................................... 43
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7.1 Literature. ............................................................................................................... 43
7.2 Interviews............................................................................................................... 43
7.3 Implementing the new guidelines ........................................................................... 45
7.4 Benchmark model .................................................................................................. 45
8 Conclusion .................................................................................................................... 47
8.1 Design method ....................................................................................................... 47
8.2 Benchmark model .................................................................................................. 47
8.3 General ................................................................................................................... 48
9 References ..................................................................................................................... 49
Appendix ................................................................................................................................ I
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