​​The image shows two additive manufacturing test builds, using a a microstructural-crystallographic characterisation technique. 
​Image​ credit: Eduard Hrhya, Chalmers

Design for additive manufacturing

We establish basic criteria for choosing powder bed metal additive manufacturing (AM). By understanding interlink between material properties and process parameters, we develop design preparation guidelines with focus on increased productivity with improved component properties (performance, surface quality, etc.). 

Significant efforts are required to develop the process for a specific component in specific AM machine using a specific AM material. One key issue at the current state-of-the-art in AM is the absence of material- and process-based guidelines for selection of the AM route for specific product, that are based on the application, required performance, geometry, surface characteristics, cost, etc. Such a guidelines will allow to significantly increase confidence in the technology readiness for integration of AM in a manufacturing process chain and widen the product portfolio for AM.

Image right: Microstructure of the thin wall (0.2 to 2 mm) and inclines structures in case of laser powder bed fusion built in 316L.

Three initiatives

​In each research area there are specific ongoing initiatives. In this area, there are three:

  1. Additive manufacturing design constrains and CAD preparation
    The focus is placed on the geometrical constrains when it comes to the single component design and its orientation on component buildability, cost and quality. In particular, geometrical constrains related to the component size, required component re-design to suit specific powder bed AM technology (EBM, LS or LMD), component lightning (internal features and hollow structures) and cellular structures, wall thickness and their orientation in the build chamber, geometry and design of the cooling channels, etc. 
  2. Components performance and CAD design
    The focus of this activity is placed on the establishment of the relationship between the process parameters on the microstructure and mechanical performance of the components containing design-specific features as lattice structures and thin walls as well as effect of the component orientation on the surface quality. Design and effect of the support structures on the materials performance is studied as well. 
  3. CAD design for robust manufacturing
    In powder bed AM manufacturing process, orientation of the surface on the building plate has significant effect on the surface quality and surface finish of the component. Hence, focus of this activity is placed on the establishment of the relationship between the CAD design of a single component and its integration in the AM manufacturing process with the aim on maximizing high productivity without significantly compromising component performance. Component orientation has to be carefully designed in order to maximize the number of the components in the build volume without affecting finish of the sensitive surfaces for the component as well as heat concentration management, influencing microstructure. 

Research Area Leaders 

Dr Marie Fischer, Dr. Fiona Schulz, Prof. Eduard Hryha, Chalmers, and Niklas Johansson, Siemens

Researchers involved

Alexander Leicht, PhD Student, Chalmers (defended 2020)
Dr Marie Fischer, post-doc, Chalmers (finished 2020)
Dr Fiona Schulz, post-doc, Chalmers (finished 2022)
Prof. Eduard Hryha, Chalmers
Prof. Lars Nyborg, Chalmers
Prof. Uta Klement, Chalmers

Partners involved

Rise IVF, Siemens, Volvo Cars, Alfa Laval, Sandvik, Volvo, Epiroc, SAAB, Brogrens, Ortoma, Modul Systems, Cascade Control

Page manager Published: Mon 28 Feb 2022.