Senvol used to demonstrate airworthiness of multi-laser additively manufactured parts for US Air Force

June 29, 2020

Senvol, New York, USA, reports that its data-driven machine learning software for Additive Manufacturing, Senvol ML™, is being used to assist with a U.S. Air Force programme focused on developing methodology for demonstrating airworthiness of components produced on multi-laser AM machines. 

As part of a collaboration between Air Force Research Laboratory (AFRL) and Air Force Life Cycle Management Center (AFLCMC), the “FlexSpecs” programme is focused on qualifying an EOS M400-4 quad laser Powder Bed Laser Fusion (PB-LF) machine. The goal is to develop baseline mechanical properties and design allowables, and ultimately make demonstration builds of heat exchangers and hypersonics-relevant parts. 

The prime contractor on the programme is the University of Dayton Research Institute (UDRI). Jessica Orr, Program Manager and Materials Engineering Team Leader for AM & Repair Technologies at UDRI, stated, “AM has recently demonstrated the ability to rapidly deliver complex geometries and production quality parts that are able to enhance the capabilities of DoD weapons systems.” 

“A major challenge facing the use of AM for producing DoD relevant end-use parts is that the number of available large scale printers is likely to be limited for the next five to ten years. In this collaborative programme we are developing and demonstrating methodology to use a new multi-laser AM printer to produce airworthy, end-use parts,” she added.

According to Senvol, its software is being employed to assist with the development of the process optimisation and characterisation plan and to analyse all project data. 

Annie Wang, Senvol President, stated, “We’re thrilled to work with UDRI, AFRL, and AFLCMC on this programme. Our machine learning software, Senvol ML, is well-suited to assist with AM qualification, and this is a great example of that. In addition to helping to develop baseline mechanical properties and design allowables, the software will analyse data to evaluate laser-to-laser consistency, optimise bulk scan settings, identify preferred overlap patterns and parameters, and confirm uniformity over the entire build plate.”

Dr Mark Benedict, Materials Scientist and Program Manager in the Propulsion, Structures & Industrial Technologies Branch, Manufacturing Technology Division, Materials and Manufacturing Directorate, AFRL, Air Force Materiel Command, noted, “The overall objective of this programme is to successfully demonstrate full scale M400, multi-laser prints of heat exchangers as well as hypersonics-relevant parts. This is an area of need for the Air Force, and we look forward to the results.”

Download the latest issue of Metal AM magazine

Our latest issue is now available to view online or download in PDF format.

As well as an extensive AM industry news section, this 184-page issue includes articles and reports on:

  • Cheaper powders, faster build speeds and no thermal stresses? How AM is going supersonic at SPEE3D
  • Current perspectives on metal AM: Hype, volume manufacturing and the geographies of production
  • AM Ventures: An insider’s perspective on venture capital for start-ups in Additive Manufacturing
  • Binder Jetting and beyond: Optimising the use of metal powders for Additive Manufacturing
  • From lightweighting and material efficiency to energy consumption: Where are we on AM’s sustainability journey?
  • AM’s industrial impact celebrated as Sweden hosts ASMET’s fourth Metal Additive Manufacturing Conference
  • Euro PM2019: Effects of humidity and storage conditions on Additive Manufacturing powder quality
  • > More information

Latest news


    Sign up to our e-newsletter, sent weekly to AM professionals and end-users around the world. We'll also let you know each time a new issue of Metal AM magazine is available.

    Discover our magazine archive…

    The free to access Metal Additive Manufacturing magazine archive offers unparalleled insight into the world of metal Additive Manufacturing from a commercial and technological perspective through:
    • Reports on visits to leading metal AM part manufacturers and industry suppliers
    • Articles on technology and application trends
    • Information on materials developments
    • Reviews of key technical presentations from the international conference circuit
    • International industry news
    All past issues are available to download in PDF format, in either single page format or as double-page “spreads” for viewing on large monitors. All downloads are free of charge. Go to archive...

    Connect with us

    Visit our social media channels and sign up to our e-newsletter

    Copy link
    Powered by Social Snap