Control-Oriented Modeling and Repetitive Control in In-Layer and Cross-Layer Thermal Interactions in Selective Laser Sintering

2020 ◽  
Vol 1 (1) ◽  
Author(s):  
Dan Wang ◽  
Tianyu Jiang ◽  
Xu Chen
Keyword(s):  
High Performance ◽  
Selective Laser Sintering ◽  
Repetitive Control ◽  
Three Dimensional ◽  
Process Variations ◽  
Laser Sintering ◽  
Laser Source ◽  
Cross Layer ◽  
Modeling And Control ◽  
Melt Pool

Abstract Although laser-based additive manufacturing (AM) has enabled unprecedented fabrication of complex parts directly from digital models, broader adoption of the technology remains challenged by insufficient reliability and in-process variations. In pursuit of assuring quality in the selective laser sintering (SLS) AM, this paper builds a modeling and control framework of the key thermodynamic interactions between the laser source and the materials to be processed. First, we develop a three-dimensional finite element simulation to understand the important features of the melt pool evolution for designing sensing and feedback algorithms. We explore how the temperature field is affected by hatch spacing and thermal properties that are temperature-dependent. Based on high-performance computer simulation and experimentation, we then validate the existence and effect of periodic disturbances induced by the repetitive in- and cross-layer thermomechanical interactions. From there, we identify the system model from the laser power to the melt pool width and build a repetitive control algorithm to greatly attenuate variations of the melt pool geometry.

Selection of selective laser sintering materials for different applications

2015 ◽  
Vol 21 (6) ◽  
pp. 630-648 ◽  
Author(s):  
Sunil Kumar Tiwari ◽  
Sarang Pande ◽  
Sanat Agrawal ◽  
Santosh M. Bobade
Keyword(s):  
Process Parameters ◽  
High Performance ◽  
Material Selection ◽  
Selective Laser Sintering ◽  
Laser Sintering ◽  
Optimal Process ◽  
Content Type ◽  
Volume Production ◽  
High Performance Application ◽  
Selection Of

Purpose – The purpose of this paper is to propose and evaluate the selection of materials for the selective laser sintering (SLS) process, which is used for low-volume production in the engineering (e.g. light weight machines, architectural modelling, high performance application, manufacturing of fuel cell, etc.), medical and many others (e.g. art and hobbies, etc.) with a keen focus on meeting customer requirements. Design/methodology/approach – The work starts with understanding the optimal process parameters, an appropriate consolidation mechanism to control microstructure, and selection of appropriate materials satisfying the property requirement for specific application area that leads to optimization of materials. Findings – Fabricating the parts using optimal process parameters, appropriate consolidation mechanism and selecting the appropriate material considering the property requirement of applications can improve part characteristics, increase acceptability, sustainability, life cycle and reliability of the SLS-fabricated parts. Originality/value – The newly proposed material selection system based on properties requirement of applications has been proven, especially in cases where non-experts or student need to select SLS process materials according to the property requirement of applications. The selection of materials based on property requirement of application may be used by practitioners from not only the engineering field, medical field and many others like art and hobbies but also academics who wish to select materials of SLS process for different applications.

scholarly journals Estimation of the compression strength and surface roughness of the as-built SLS components using weibull distribution

2021 ◽  
pp. 1-6
Author(s):  
Hamaid Mahmood KHAN
Keyword(s):  
Mechanical Properties ◽  
Surface Roughness ◽  
Compressive Strength ◽  
Weibull Distribution ◽  
Selective Laser Sintering ◽  
Three Dimensional ◽  
Random Variable ◽  
Production Quality ◽  
Laser Source ◽  
Distribution Method

Selective laser sintering (SLS) is a process of fabrication of three-dimensional structures by fus- ing powder particles using a guided laser source. The uncertainty in the mechanical properties of the SLS parts fabricated at the same time and with the same process parameters can affect the repeatability of the SLS process. A vast difference in the mechanical properties of the concurrently processed parts can lower the production quality of the batch. Therefore, the param- eters are required to be design based on the most probable outcome of the desired properties. Weibull distribution is one such statistical-based probability distribution method to measure the likelihood of the occurrence of a value of any random variable falling within a particular range of values. Here, the Weibull distribution was used to measure the relative likelihood (90% probability) of the surface roughness and the compressive strength values of the SLS-built polyamide PA2200 components in the given sample space that was obtained from 20 random samples. The results show that the variance in the surface roughness (scan and built plane) and the compressive strength values were in the range of 6–7 μm and around 10 MPa, respectively. Moreover, the surface roughness of the two orthogonal planes with 90% reliability was measured at 14.81 μm (scan plane) and 12.15 μm (built plane). Similarly, the yield strength and the compressive strength with 90% reliability were found 25.87 MPa and 62.64 MPa, respectively.

scholarly journals Advanced Trans-Tibial Socket Fabrication Using Selective Laser Sintering

2007 ◽  
Vol 31 (1) ◽  
pp. 88-100 ◽  
Author(s):  
Bill Rogers ◽  
Gordon W. Bosker ◽  
Richard H. Crawford ◽  
Mario C. Faustini ◽  
Richard R. Neptune ◽  
...  
Keyword(s):  
Solid Freeform Fabrication ◽  
Selective Laser Sintering ◽  
Three Dimensional ◽  
Structural Features ◽  
Laser Sintering ◽  
Health Science ◽  
Science Center ◽  
University Of Texas ◽  
Three Dimensional Objects ◽  
Prosthetic Socket

There have been a variety of efforts demonstrating the use of solid freeform fabrication (SFF) for prosthetic socket fabrication though there has been little effort in leveraging the strengths of the technology. SFF encompasses a class of technologies that can create three dimensional objects directly from a geometric database without specific tooling or human intervention. A real strength of SFF is that cost of fabrication is related to the volume of the part, not the part's complexity. For prosthetic socket fabrication this means that a sophisticated socket can be fabricated at essentially the same cost as a simple socket. Adding new features to a socket design becomes a function of software. The work at The University of Texas Health Science Center at San Antonio (UTHSCSA) and University of Texas at Austin (UTA) has concentrated on developing advanced sockets that incorporate structural features to increase comfort as well as built in fixtures to accommodate industry standard hardware. Selective laser sintering (SLS) was chosen as the SFF technology to use for socket fabrication as it was capable of fabricating sockets using materials appropriate for prosthetics. This paper details the development of SLS prosthetic socket fabrication techniques at UTHSCSA/UTA over a six-year period.

Dimensional error of selective laser sintering, three-dimensional printing and PolyJet™ models in the reproduction of mandibular anatomy

2009 ◽  
Vol 37 (3) ◽  
pp. 167-173 ◽  
Author(s):  
Danilo Ibrahim ◽  
Tiago Leonardo Broilo ◽  
Claiton Heitz ◽  
Marília Gerhardt de Oliveira ◽  
Helena Willhelm de Oliveira ◽  
...  
Keyword(s):  
Selective Laser Sintering ◽  
Three Dimensional ◽  
Laser Sintering ◽  
Dimensional Error ◽  
Three Dimensional Printing ◽  
Dimensional Printing

Three-Dimensional Modeling of Selective Laser Sintering of Two-Component Metal Powder Layers

2005 ◽  
Vol 128 (1) ◽  
pp. 299-306 ◽  
Author(s):  
Tiebing Chen ◽  
Yuwen Zhang
Keyword(s):  
Metal Powder ◽  
Continuous Wave ◽  
Selective Laser Sintering ◽  
Three Dimensional ◽  
Laser Sintering ◽  
Powder Layer ◽  
Metal Powders ◽  
Gaussian Laser Beam ◽  
Scanning Velocity ◽  
Three Dimensional Modeling

Laser sintering of a metal powder mixture that contains two kinds of metal powders with significantly different melting points under a moving Gaussian laser beam is investigated numerically. The continuous-wave laser-induced melting accompanied by shrinkage and resolidification of the metal powder layer are modeled using a temperature-transforming model. The liquid flow of the melted low-melting-point metal driven by capillary and gravity forces is also included in the physical model. The numerical results are validated by experimental results, and a detailed parametric study is performed. The effects of the moving heat source intensity, the scanning velocity, and the thickness of the powder layer on the sintering depth, the configuration of the heat affected zone, and the temperature distribution are discussed.

Three dimensional printing of carbon/carbon composites by selective laser sintering

Carbon ◽  
2016 ◽  
Vol 96 ◽  
pp. 603-607 ◽  
Author(s):  
Xu Yi ◽  
Zhou-Jian Tan ◽  
Wan-Jing Yu ◽  
Jun Li ◽  
Bing-Ju Li ◽  
...  
Keyword(s):  
Selective Laser Sintering ◽  
Three Dimensional ◽  
Laser Sintering ◽  
Carbon Composites ◽  
Three Dimensional Printing ◽  
Dimensional Printing

scholarly journals Selective Laser Sintering – Binding Mechanism And Assistance In Medical Applications

2015 ◽  
Vol 15 (3) ◽  
pp. 5-16
Author(s):  
Ż. A. Mierzejewska ◽  
W. Markowicz
Keyword(s):  
Biomedical Engineering ◽  
Selective Laser Sintering ◽  
Three Dimensional ◽  
Laser Sintering ◽  
Training Models ◽  
Three Dimensional Objects ◽  
Tissue Replacement ◽  
Dental Implantation ◽  
Custom Made ◽  
Complicated Geometry

Abstract Rapid prototyping technology (RP), based on designing and computer aided manufacturing, is widely used in traditional branches of industry. Due to its ability to accurately and precisely manufacture designed elements of various dimensions and complicated geometry, this technology is more and more frequently applied in the field of biomedical engineering. Selective laser sintering (SLS) is a universal RP technique, utilizing a laser beam to sinter powdered materials and create three-dimensional objects. Data for producing parts for tissue replacement come from medical imaging capabilities and digital presentation of test results. This paper presents the following: general classification of RP methods, the concept and methodology of performing laser sintering, sintering mechanisms, and the application of elements manufactured using this technology in biomedical engineering, particularly for the production of scaffolds used in tissue cultures, skeletal and dental prostheses in dental implantation, manufacturing of custom-made implants that are individually adjusted to the patient, and for production of training models on which a team of surgeons can train a surgical technique.

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