Design and Material Performance for Lightweight in Powder Bed Metal Additive Manufacturing

Purpose and goal

The project aimed to demonstrate the possibilities and limits of metal additive manufacturing regarding wall thickness and surface finish. Another target has also been to increase productivity through increased layer thickness without compromising material and product properties. In all, the project has been able to demonstrate intended effects. Also, demonstrators have been produced, demonstrating increased productivity for complex geometry as well as vary good fine-scale capability for the technique. Results have also been presented in international publications.

Expected results and effects

The project has meant steps towards future industrialization of metal additive manufacturing. The target has been on specific limits of the technology that are central to creating new products such as thin walls and to surface fineness/precision. The focus on these critical factors and shown results have created conditions for product design for lightweight and new functional products and also showed how increased productivity can be achieved through process development, involving strengthened research and innovation agenda.

Planned approach and implementation

The focus has been on laser powder bed fusion. Chalmers, RISE, LU and Siemens have built samples and demonstrators. Höganäs has provided metal powder and characterisation. RISE has studied how surface finish can be tuned and its effect on properties. Chalmers has connected wall thickness, properties and microstructure. Alfa Laval and SAAB have addressed product design, evaluation and also functional testing or modelling. MSC has been responsible for process modelling. Connecting the knowledge with final demonstrators has prepared for upscaling and further development