Challenges in Metal Additive Manufacturing (2017)

Definition: 2D additive patterning and 3D components by laser layered additive manufacturing, including both SLM and LMD.

General Challenges

1. Resolution, accuracy, distortion and surface finishing;
2. Multiple materials and multi-functional materials;
3. Productivity;
4. Residual stresses and scanning strategy resulting in minimum distortion;
5. Control of resulting microstructure;
6. Surface finish/quality;
7. In-process monitoring for defects (e.g. cracks, porosity).

Challenges in SLM (Selective Laser Melting)

1. Process fundamentals (e.g. melting, solidification, keyhole);
2. Platform size;
3. Simulation, design, and “digital material” concepts;
4. Software: from CAD to the product and back;
5. Powder quality and price;
6. Multi-material printing (“color printer”);
7. Post-processing (shape, support structure, surface);
8. In-product surface finishing.

Challenges in LMD (Laser Metal Deposition)

1. Micro cracks;
2. Thermal management;
3. Surface finishing;
4. 2½ to 3D structures;
5. High entropy materials (thin layers).