Exploring Additive Manufacturing Processes for Direct 3D Printing of Copper Induction Coils

2017 ◽  
Author(s):  
John D. Martin
Keyword(s):  
Additive Manufacturing ◽  
3D Printing ◽  
Electron Beam Melting ◽  
Energy Deposition ◽  
Manufacturing Processes ◽  
Powder Bed Fusion ◽  
Laser Melting ◽  
Powder Bed ◽  
Computer Aided ◽  
Directed Energy

A number of additive manufacturing processes were analyzed and compared in regards to the direct 3D printing of copper induction coils. The purpose of this study was to narrow in on 3D printing technologies that would best be suited for the manufacture of copper inductions coils. The main focus of the study was to look at how all the available additive processes could specifically be successful at creating parts made of copper pure enough to effectively conduct electricity and also geometries complex enough to meet the demands of various induction coil designs. The results of this study led to three main categories of additive manufacturing that were deemed good choices for producing copper induction coils, these included: powder bed fusion, sheet lamination, and directed energy deposition. Specific processes identified within these categories were powder bed fusion using electron beam melting and laser melting; ultrasonic additive manufacturing; and directed energy deposition utilizing laser melting and electron beam melting using both wire and powder material delivery systems. Also discussed was additional benefits that using 3D printing technology could provide beyond the physical manufacturing portion by opening doors for coupling with computer aided drafting (CAD) and computer aided engineering (CAE) software in order to create a seamless design-to-production process.

scholarly journals Additive Manufacturing Processes in Medical Applications

Materials ◽  
2021 ◽  
Vol 14 (1) ◽  
pp. 191
Author(s):  
Mika Salmi
Keyword(s):  
Additive Manufacturing ◽  
Energy Deposition ◽  
Manufacturing Processes ◽  
Medical Applications ◽  
Powder Bed Fusion ◽  
Powder Bed ◽  
Material Extrusion ◽  
Fusion Material ◽  
Directed Energy ◽  
Binder Jetting

Additive manufacturing (AM, 3D printing) is used in many fields and different industries. In the medical and dental field, every patient is unique and, therefore, AM has significant potential in personalized and customized solutions. This review explores what additive manufacturing processes and materials are utilized in medical and dental applications, especially focusing on processes that are less commonly used. The processes are categorized in ISO/ASTM process classes: powder bed fusion, material extrusion, VAT photopolymerization, material jetting, binder jetting, sheet lamination and directed energy deposition combined with classification of medical applications of AM. Based on the findings, it seems that directed energy deposition is utilized rarely only in implants and sheet lamination rarely for medical models or phantoms. Powder bed fusion, material extrusion and VAT photopolymerization are utilized in all categories. Material jetting is not used for implants and biomanufacturing, and binder jetting is not utilized for tools, instruments and parts for medical devices. The most common materials are thermoplastics, photopolymers and metals such as titanium alloys. If standard terminology of AM would be followed, this would allow a more systematic review of the utilization of different AM processes. Current development in binder jetting would allow more possibilities in the future.

Sensing for directed energy deposition and powder bed fusion additive manufacturing at Penn State University

2016 ◽  
Author(s):  
Abdalla R. Nassar ◽  
Edward W. Reutzel ◽  
Stephen W. Brown ◽  
John P. Morgan ◽  
Jacob P. Morgan ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Energy Deposition ◽  
Powder Bed Fusion ◽  
State University ◽  
Powder Bed ◽  
Directed Energy Deposition ◽  
Penn State ◽  
Directed Energy

Analysis of defect generation in Ti–6Al–4V parts made using powder bed fusion additive manufacturing processes

2014 ◽  
Vol 1-4 ◽  
pp. 87-98 ◽  
Author(s):  
Haijun Gong ◽  
Khalid Rafi ◽  
Hengfeng Gu ◽  
Thomas Starr ◽  
Brent Stucker
Keyword(s):  
Additive Manufacturing ◽  
Manufacturing Processes ◽  
Powder Bed Fusion ◽  
Powder Bed ◽  
Defect Generation

scholarly journals Laser powder bed fusion additive manufacturing of copper wicking structures: fabrication and capillary characterization

2021 ◽  
Author(s):  
Adnen Mezghani
Keyword(s):  
Additive Manufacturing ◽  
Performance Analysis ◽  
Heat Pipes ◽  
Manufacturing Processes ◽  
Powder Bed Fusion ◽  
Laser Powder Bed Fusion ◽  
Powder Bed ◽  
Published Report ◽  
Secondary Manufacturing ◽  
Design Freedom

PurposeAn integral component in heat pipes (HPs) and vapor chambers (VCs) is a porous wicking structure. Traditional methods for manufacturing wicking structures within HPs and VCs involve secondary manufacturing processes and are generally limited to simple geometries. This work aims to leverage the unprecedented level of design freedom of laser powder bed fusion (LPBF) additive manufacturing (AM) to produce integrated wicking structures for HPs and VCs.Design/methodology/approachCopper wicking structures are fabricated through LPBF via partial sintering and via the formation of square, hexagonal and rectangular arrangements of micro-pins and micro-grooves, produced in multiple build directions. Wicks are characterized by conducting capillary performance analysis through the measurement of porosity, permeability and capillary rate-of-rise.FindingsCopper wicking structures were successfully fabricated with capillary performance, K/reff, ranging from 0.186–1.74 µm. The rectangular-arrangement micro-pin wick presented the highest performance.Originality/valueThis work represents the first published report on LPBF AM of copper wicking structures for HPs/VCs applications and represents foundational knowledge for fabricating complete assemblies of copper VCs and HPs through LPBF AM.

Hybride Fertigung mittels Laser-Strahlschmelzen/Hybrid manufacturing by laser-based powder bed fusion

2021 ◽  
Vol 111 (06) ◽  
pp. 363-367
Author(s):  
Lukas Langer ◽  
Matthias Schmitt ◽  
Georg Schlick ◽  
Johannes Schilp
Keyword(s):  
Additive Manufacturing ◽  
Manufacturing Processes ◽  
Complex Geometries ◽  
Hybrid Manufacturing ◽  
Powder Bed Fusion ◽  
Process Chain ◽  
Manufacturing Costs ◽  
Additive Fertigung ◽  
Powder Bed

Die additive Fertigung ermöglicht komplexe Geometrien und individualisierte Bauteile. Die hohen Material- und Fertigungskosten können ein Hindernis für einen wirtschaftlichen Einsatz sein. In der hybriden additiven Fertigung werden die Vorteile konventioneller sowie additiver Fertigungsverfahren kombiniert. Für eine weitere Steigerung der Wirtschaftlichkeit und Effizienz werden nichtwertschöpfende Schritte der Prozesskette identifiziert und Automatisierungsansätze entwickelt.   Additive manufacturing enables complex geometries and individualized components. However, high material and manufacturing costs can be a hindrance for economical use. Hybrid additive manufacturing combines the advantages of conventional with additive manufacturing processes. For a further increase in profitability and efficiency, non-value-adding steps in the process chain are identified and automation approaches developed.

Sign in / Sign up

Export Citation Format

Share Document