Software

Metal Additive Manufacturing: A simulation provider’s perspective

Over the past few years, metal Additive Manufacturing has received a lot of attention, and with good reason: the technology has the potential to radically alter the design and production of components and products in many industries. Yet in spite of the excitement that surrounds AM, the prospect of wider industrial adoption continues to face significant challenges. Ansys Inc’s Dave Conover explains how simulation, traditionally the domain of product design instead of manufacturing, has swiftly gained recognition as a key technology which can be used to ease the transition from conventional to Additive Manufacturing [First published in Metal AM Vol. 4 No. 3, Autumn 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 »

The 1st Munich Technology Conference: AM is on course for broad industrial use

More than 600 international metal AM professionals gathered in October for the 1st Munich Technology Conference. Organised and sponsored by Oerlikon, the aim of this unique event was to provide a dedicated platform for the discussion and sharing of best practices in AM production and applications, along with the business models needed to drive the industrialisation of AM. We invited Prof Dr-Ing Michael Zäh, Chair of Machine Tools and Production Technology at the Technical University of Munich, to consider the status of metal AM as revealed over the event’s two days of presentations and discussions [First published in Metal AM Vol. 3 No. 4, Winter 2017] ... Read more »

The inspection and quality control of metal AM parts with X-ray Computed Tomography (micro CT)

X-ray Computed Tomography (micro CT) is just one option for the inspection of metal AM parts. Other options include using eddy current, ultrasonic technology, white-light interferometry and non-interferometric optics. However, given recent developments, it is micro CT that has the most potential in view of its unique capability for the inspection of complex internal structures and geometries without destroying the part. The capabilities of this inspection method are presented by Andrew Ramsey and Herminso Villarraga-Gomez of Nikon Metrology Inc. [First published in Metal AM Vol. 3 No. 2, Summer 2017] ... Read more »

Accelerating AM component design workflow with new optimisation technology

Additive Manufacturing promises huge benefits for industry, but exploiting these in practice can prove difficult. For example, although truss-like component forms will often be found to be much more structurally efficient than traditional forms, identifying these has thus far been laborious and time-consuming. However, a new optimisation approach means that engineers can now directly identify optimised truss forms for AM components, saving time and effort. Prof. Matthew Gilbert of LimitState and the Advanced Additive Manufacturing (AdAM) Centre at the University of Sheffield outlines the technology and its application [First published in Metal AM Vol. 3 No. 1, Spring 2017] ... Read more »

Modelling the mechanical behaviour of additively manufactured cellular structures

One of the most promising aspects of Additive Manufacturing is the design freedom it enables. One manifestation of this design freedom lies in our ability to manufacture cellular structures such as lattices and honeycombs. Implementing cellular structures with AM, however, poses a range of design and manufacturing challenges. In this article Dr Dhruv Bhate, from Phoenix Analysis & Design Technologies, Inc. (PADT), focuses on a key area connecting design and manufacturing to final part implementation – the mechanical behaviour of these structures and the challenges and approaches to developing a reliable way to predict it [First published in Metal AM Vol. 2 No. 4, Winter 2016] ... Read more »

Cost and practicality of in-process monitoring for metal Additive Manufacturing

Additive Manufacturing gives industrial designers the freedom to create ever more complex and customised products. However, with the increasing adoption of the technology by sectors such as aerospace, where product failure can have catastrophic consequences, component verification is becoming a critical issue. In the following article Dr Chris Hole, from the UK’s TTP Group plc, reviews the challenges of verification in an industry that is associated with low volume runs of complex, often highly customised components with sophisticated hidden internal structures [First published in Metal AM Vol. 2 No. 4, Winter 2016] ... Read more »

FIT AG: Laying the foundations for high-volume metal Additive Manufacturing

There is no doubt that the Additive Manufacturing of series components is quickly becoming a reality. From high-profile applications in the aerospace industry to performance components for the automotive sector, there are now numerous examples of the successful implementation of metal AM. However, the route that a company chooses in order to adopt AM technology could have a significant impact on a component’s development time and cost. As Nick Williams reports, Germany’s FIT AG sees opportunities in leveraging its expertise to supporting companies with the outsourcing of component development and production. To achieve this, the company has created a model AM factory that it plans to replicate worldwide [First published in Metal AM Vol. 2 No. 3, Autumn 2016] ... Read more »

Planning, preparing and producing: Walking the tightrope between additive and subtractive manufacturing

In the following article Delcam’s Kelvin Hamilton explores the current possibilities for design, topology optimisation, simulation, process planning and process preparation in metal Additive Manufacturing (AM). Exploring the three Ps, Plan, Prepare and Produce, all the processes involved in transforming three airbrake bracket designs into final products are revealed. As well as explaining how important it is to appreciate and plan for the significant amount of subtractive manufacturing in metal AM, a number of the lessons learnt in this project are discussed as the author reflects on the experience of planning, preparing and producing parts [First published in Metal AM Vol. 2 No. 1, Spring 2016] ... Read more »

Process and quality control for AM: Sigma Labs PrintRite3D® methodology for overall quality assurance

Despite the outstanding promise of metal Additive Manufacturing technologies, inconsistent quality, process reliability and speed are currently holding back industry growth and impacting on the cost-effectiveness of new applications. In the following article Sigma Labs’ Dr Vivek R Dave and Mark J Cola review the technical challenges that are faced in enabling metal AM to reach its full potential and the systems that are currently available to address a number of critical issues [First published in Metal AM Vol. 2 No. 1, Spring 2016] ... 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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    • Information on materials developments
    • Reviews of key technical presentations from the international conference circuit
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