Design for AM

Siemens: Digitalisation enables the industrialisation of metal Additive Manufacturing at Finspång

As one of the world’s largest industrial companies, Siemens has experienced first hand the process of taking metal AM from the R&D laboratory to the series production of critical components for its power generation business. Today, it is supporting the global industrialisation of the technology through its Siemens NX Additive Manufacturing software. In the following report the company’s Aaron Frankel and Ashley Eckhoff explain their belief that, whilst the potential of AM is massive, digitalisation will play a critical role in enabling its transition from a prototyping tool to a serial production technology [First published in Metal AM Vol. 4 No. 3, Autumn 2018] ... Read more »

Conformal cooling: How AM is increasing efficiency and quality in the injection moulding industry

Much of the early success for metal Additive Manufacturing came from tool and die applications and this sector continues to offer significant growth potential for the industry. In this report, Jarod Rauch, from tool and die manufacturer B&J Speciality Inc, and David Lindemann, 3D Systems, share their thoughts on the current status and future potential of AM conformal cooling solutions with Metal AM magazine’s Nick Williams [First published in Metal AM Vol. 4 No. 3, Autumn 2018] ... Read more »

Additive Manufacturing: Myths, misconceptions and untruths

The past decade has seen tremendous growth in metal Additive Manufacturing. To a certain degree, the field has become a victim of its own success, resulting in a number of myths, misconceptions and untruths. Some of these are even becoming detrimental to the further adoption of AM around the world. Olaf Diegel and Terry Wohlers draw on their combined industry experience to address the ten most common misunderstandings and myths relating to AM and present the reality of the technology at its current stage [First published in Metal AM Vol. 4 No. 3, Autumn 2018] ... Read more »

Poly-Shape: Metal Additive Manufacturing for the high-performance motorsport industry

In a little over ten years, France’s Poly-Shape has grown into one of Europe’s leading manufacturers of AM components. With more than thirty metal AM systems installed across four plants, the company is a key supplier to top-tier motorsports, from Formula 1 and IndyCar to World Rallycross and the Pikes Peak International Hill Climb. In the following article, the company presents a series of case studies highlighting the use of metal AM in this sector, and reveals its approach to the technology and plans for the future [First published in Metal AM Vol. 4 No. 2, Summer 2018] ... Read more »

Design for Additive Manufacturing presents opportunities for software developments

Designing a component for AM whilst taking advantage of all the opportunities that the technology presents can result in many variables. Even a group of experienced Design for Additive Manufacturing (DfAM) experts will end up with significantly different build strategies for an identical part. In the following article, Olaf Diegel and Terry Wohlers consider how software innovations could further streamline the AM process, from part positioning and stress management to surface finish considerations and quality control ... Read more »

How process parameters drive successful metal AM part production

A number of factors drive the selection of process parameters in Laser Powder Bed Fusion (LPBF). In this invaluable resource Marc Saunders, Renishaw plc’s Director of Global Solutions Centres, details how these parameters define the ‘operating window’ in which AM users must work, and offers advice on identifying the ideal process parameters for metal AM parts. The sensitivity of the process to changes in part geometry is also considered, along with how this may drive part developers towards application-specific parameter choices [First published in Metal AM Vol. 4 No. 2, Summer 2018] ... Read more »

Sauber Motorsport AG and Additive Industries: Formula 1® engineering meets metal AM

As the new Formula 1 season gets underway, Additive Manufacturing will have played a vital role in the development and manufacture of the cars on track. Metal AM magazine’s Nick Williams recently visited Sauber Motorsport AG at its headquarters near Zürich, Switzerland, and discovered how a partnership with Dutch AM technology supplier Additive Industries has supported both the development of in-house AM applications and an expansion of Sauber Motorsport’s AM services for third parties [First published in Metal AM Vol. 4 No. 1, Spring 2018] ... Read more »

Component design for cost-efficient metal Additive Manufacturing

Some companies approach Additive Manufacturing as a drop-in replacement for conventional manufacturing technologies. This approach, however, does not take into account the unique possibilities that additive processes offer and can result in parts that are not commercially viable due to cost. By designing parts specifically for AM, companies can reduce costs and improve efficiency while taking advantage of the possibilities offered by the technology. In this report, Olaf Diegel and Terry Wohlers look at the impact of good AM part design on machine operating costs [First published in Metal AM Vol. 4 No. 1, Spring 2018] ... Read more »

Case Study: Cooling channels for material testing applications using Laser Powder Bed Fusion

Additive Manufacturing continues to gain a reputation as a key technology that will have a major impact on all aspects of mechanical engineering. Under the guidance of Major Ryan O’Hara, the United States Air Force’s (USAF) Air Force Institute of Technology (AFIT), based in Dayton, Ohio, has expanded its AM-focused education and R&D capabilities with the purchase of a Laser Powder Bed Fusion system from Germany’s Concept Laser. In the following article, AFIT’s Benjamin Doane and colleagues highlight work done at the institute to develop AM test bed components to support a high temperature testing programme [First published in Metal AM Vol. 4 No. 1, Spring 2018] ... Read more »

Costs and considerations when investing in a metal Additive Manufacturing system

Making the investment in a metal Additive Manufacturing machine is, for many, the first step on a journey to truly understanding how the technology can transform a business. There are, however, many considerations when planning such an investment; from essential ancillary equipment and devices, such as sieving stations, to facility changes, software and support. In this exclusive report, Terry Wohlers and Olaf Diegel highlight some of the commonly overlooked costs and considerations when making the move to establish an in-house AM capability [First published in Metal AM Vol. 3 No. 4, Winter 2017] ... Read more »

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 204-page issue includes articles and reports on:

  • Optimised thermal management in semiconductor fabrication using AI-enabled generative design and Additive Manufacturing
  • Forging a process for mass customisation via metal Additive Manufacturing
  • Bringing it all together: How Materialise is integrating manufacturing and software expertise to shape AM’s future
  • Pedal to the metal at the Digital Manufacturing Centre: Redefining what’s possible for AM in hypercars and beyond
  • The future is Additive Manufacturing – if we take a more holistic view of the design opportunities
  • Building a case for radical collaboration plus quality standards: The pathway to growing the AM industry
  • Distributed manufacturing: Old concept, new relevance, new technology?
  • Design for Additive Manufacturing: A workflow for a metal AM heat exchanger using nTopology (BJT)
  • Taking the holistic view:
    Defining the state-of-the-art in the evolving PBF-LB machine marketplace
  • > More information

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    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:
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