Additive
manufacturing
Metal Additive Manufacturing: Shaping the Future of
Aerospace and Automotive Industries
Group 5
December 1, 2023
Introduction
• Additive manufacturing, commonly known as 3D printing
• It is a revolutionary process that constructs objects layer
by layer from digital models
• Offering unprecedented design flexibility and
manufacturing capabilities.
2
Types of additive manufacturing
• POWDER BED FUSION
• MATERIAL EXTRUSION
• DIRECTED ENERGY DEPOSITION
• VAT PHOTOPOLYMERIZATION
• SHEET LAMINATION
• MATERIAL JETTING
• BINDER JETTING
3
Advantages of
additive
manufacturing
Design Flexibility: Weight Reduction:
Enables complex and intricate geometries that are Facilitates lightweight designs by optimizing internal
impossible to achieve with traditional methods structures, improving fuel efficiency in aerospace and
automotive applications
Material Efficiency: Cost-Effective for Low-Volume Production:
Reduces material waste as objects are built layer by Ideal for low-volume or small-batch production without
layer, minimizing the need for subtractive processes the need for expensive tooling
Rapid Prototyping and Iteration:
Specially in Aerospace and Automotive industry, allows
for quick prototyping and iterative design changes
without the need for new tooling
4
Additive Manufacturing vs
Mass production methods
5
What materials are
commonly used in AM?
Aerospace Automotive
Material Applications Material Applications
Engine components, body panels, chassis
Titanium Alloys Structural parts, engine components Aluminum Alloys
elements
Nickel-Based Alloys Gas turbine components, engine parts Various automotive components, structural
Steel Alloys
elements
Aluminum Alloys Airframe components Titanium Alloys Exhaust systems, lightweight components
Gas turbine components, high-
Inconel Polymer-Based Materials Prototyping, interior components
temperature applications
Stainless Steel Brackets, housings Carbon Fiber Reinforced
Body panels, structural parts
Polymers (CFRP)
Composites Structural components, lightweight parts Copper Alloys Electrical connectors, heat exchangers
Components requiring high temperature
Cobalt-Chrome Alloys Aerospace turbines High-Performance Plastics
resistance
6
AM applications in Aerospace and
Automotive industry
Applications of Additive Applications of Additive
Manufacturing in Aerospace Manufacturing in Automotive
1. Lightweight Structural Components 1. Lightweight Components
2. Engine Components 2. Customized Components
3. Aircraft Interiors 3. Prototyping and Concept Models
4. Prototyping and Testing 4. Tooling and Jigs
5. Satellite Components 5. Performance Parts
6. Unmanned Aerial Vehicles (UAVs) 6. Brake Components
7. Repair and Maintenance 7. Customized Vehicle Accessories
8. Space Exploration 8. Spare Parts Manufacturing
7
Some of additive manufactured parts
8
Additive Manufacturing Hype Curve
9
Technology Readiness Levels
TRL stands for Technology
Readiness Level and is a
metric that was initially
pioneered by
NASA Goddard Space
Flight Centre in the 1980s to
assess readiness and risk of
space
technology
10
How Laser Powder Bed Fusion
works?
Preparation of Powder Bed
Fusion by Laser or Electron Beam
Layer-by-Layer Building
Fusion and Solidification
Lowering the Build Platform
Repeat Build Process
Support Structures (Optional)
Cooling and Post-Processing
Material Recycling
Applicability to Various Materials
High Precision
11
What Facilities we have in Swansea
University
The Renishaw’s AM450 and AM250 models that use Laser
Powder Bed Fusion technology (LPBF), with the Build
envelope size of 250 × 250 × 365 mm
“
D iscover a market which is not using additive
manufacturing technologies now, put your ideas in the
market, there are many people who are paying for the
customized products which can only be made by additive
technologies.
