Design for additive manufacturing to produce complex metal parts
Keywords:
industrial component, redesign, selective laser melting, steel powderAbstract
This paper presents a practical example of how an existing industrial metallic component should be redesigned to exploit the benefits of selective laser melting (SLM) manufacturing. The main challenges are: the component design in order to avoid the support structures, which typically anchor the surfaces, and to develop a special shape for internal channels that does not need support structure, because they are difficult or impossible to remove at the end of SLM manufacturing. The principles taken into account were the surface angles and the “raindrop” shape for the channels and holes. To test and validate the proposed method, the model was directly SLM processed from stainless steel (316L) powder. Combining principals of design for additive manufacturing and SLM process can be an efficient tool to obtain real industrial parts, while avoiding the support structures by integrating them into the surfaces. Respectively, developing new concepts of holes maintaining the same area of them as in the conventional approach.
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