Laser post-processing of metal additively manufactured parts
Lead Research Organisation:
Heriot-Watt University
Department Name: Sch of Engineering and Physical Science
Abstract
"This is a PhD research project in Physics. Additively manufactured ('3D printed') metal parts can require significant post-build finishing effort to remove the necessary supports and clean up any remaining marks. This craft based process requires a fair degree of skill and is a source of manufacturing variation, which is incompatible with medical and aerospace applications. This PhD will examine the use of laser processes to perform automated post-build finishing of AM parts. Building on work undertaken within the High Power Laser Applications research group in laser ablation and polishing, topics will include: approaches to support removal & support surface clean up; the best laser(s) for the work; laser beam delivery and positioning machine configuration; design rules for supports to facilitate automated clean up.
This project is supported by Renishaw plc, a major UK manufacturing company whose product range includes 'powder bed' additive manufacturing machines, which "3D print" parts by the so-called Selective Laser Melting (SLM) process. The project will link closely to the company, and it is expected that the student will spend short periods working at one or more of Remishaw's sites.
"
This project is supported by Renishaw plc, a major UK manufacturing company whose product range includes 'powder bed' additive manufacturing machines, which "3D print" parts by the so-called Selective Laser Melting (SLM) process. The project will link closely to the company, and it is expected that the student will spend short periods working at one or more of Remishaw's sites.
"
Studentship Projects
| Project Reference | Relationship | Related To | Start | End | Student Name |
|---|---|---|---|---|---|
| EP/P510518/1 | 01/10/2016 | 30/09/2021 | |||
| 1974539 | Studentship | EP/P510518/1 | 01/10/2017 | 30/09/2021 | Mark McDonald |
| Description | The surface finish of 3D printed metal medical implants has been improved using laser polishing. This involved designing and constructing set ups to minimize laser spot size divergence which would impact the effect of laser polishing between different shaped parts. An alternative laser source was investigated which offered a more cost effective solution. A demonstration part has been produced to show the flexibility of the process and achievable quality on a dental implant. Internal surfaces can be difficult to improve using laser processing as there is no direct line of sight. However we have demonstrated that it is possible to laser polish the internal surface of a cylinder. Thermal Modelling work has been carried out to calculate the melt pool size during the laser polishing process. This was found to match experimental results from microscope images of the polished tracks. |
| Exploitation Route | The parameters identified in this project can be used to replace or as an alternative surface finish for 3D printed metal medical implants. In future this project will investigate the effects of laser polishing on bacterial growth as well as studying the impact on material properties such as fatigue life and tensile strength. |
| Sectors | Healthcare |
| Description | Annual review meeting with industrial sponsor |
| Form Of Engagement Activity | Participation in an activity, workshop or similar |
| Part Of Official Scheme? | No |
| Geographic Reach | National |
| Primary Audience | Industry/Business |
| Results and Impact | Meeting with industrial sponsor, Renishaw, across various sites to review annual process of project |
| Year(s) Of Engagement Activity | 2018,2019 |
| Description | Fortnightly meetings with industrial sponsor, Renishaw |
| Form Of Engagement Activity | Participation in an activity, workshop or similar |
| Part Of Official Scheme? | No |
| Geographic Reach | Local |
| Primary Audience | Industry/Business |
| Results and Impact | Meeting with industrial sponsor, Renishaw, on a fortnightly basis to report on research progress |
| Year(s) Of Engagement Activity | 2018,2019,2020 |
| Description | Presented work at SRPe annual conference, Glasgow, 13 November 2019 |
| Form Of Engagement Activity | Participation in an activity, workshop or similar |
| Part Of Official Scheme? | No |
| Geographic Reach | Regional |
| Primary Audience | Postgraduate students |
| Results and Impact | The laser polishing work was presented as part of an exhibition stand at the conference, and I described it to a range of people who stopped at the stand. |
| Year(s) Of Engagement Activity | 2019 |
| URL | https://www.srpe.ac.uk/conference |