AM Unique Capabilities
Shape complexity: it is possible to build virtually any shape
Hierarchical complexity: features can be designed with shape complexity across
multiple size scales.
Various types of nano/microstructures
can be achieved by careful control of the
process parameters (e.g. laser power, scan
rate) for a particular material, and can
vary from point to point within a
structure.
• The ability to simultaneously control a part's nano/microstructure, mesostructure, and macrostructure
• simply by changing process parameters and
• CAD data is a capability of AM which is unparalleled using conventional manufacturing.
Functional complexity: functional device (not just individual piece-parts) can
be produced in one build
Material Complexity: Material can be processed one point, or one layer, at a
time as a single material or as a combination of materials
When building parts in additive manner, one always has to access to the
inside of the part.
Component can be inserted and it is possible to fabricate operational
mechanisms in come AM Processess
Pulley-driven snake-like robot
Source: Gibson.
The concept of functionally graded materials, or heterogeneous materials, has received
considerable attention.
However, manufacturing useful parts from these materials often has been problematic.
Example: Turbine blade for a jet engine
1. The outside of the blade must be resistant to high temperature and very stiff to prevent
elongation;
2. The blade root must be ductile and has high fatigue life;
3. Blade interiors must have high heat conductivity so that the blades can be cooled.
A part with complex shape that requires different material properties in
different regions. No single material is ideal for this range of properties.
A significant issue hindering the adoption of AM’s material complexity is the lack of
design and CAD tools that enable representation and reasoning with multiple
materials.