Acquisition of a Laser Powder Bed Fusion System to Transform the Additive Manufacturing Value Chain

ABSTRACT

Metal additive manufacturing (AM) has significant relevance to the missions of all branches of the Department of Defense (DoD) as it has the capability to bring parts to the warfighter more quickly and cost effectively However, DoD's goals of utilizing and deploying AM will not be achieved without substantial research and development to address the technology's current limitations, which exist at every facet of the AM value chain. The DURIP award, along with supplementary funding provided by Virginia Tech, enabled the acquisition of a reactive metal laser powder bed fusion (LPBF) AM system. The advanced AM system acquired through this program features open-access to all process parameters and features integrated in-situ monitoring technologies that enable research focused in increasing materials selection, creating new design for AM tools and methods, enhancing part quality through process-property-structure models, in-situ monitoring and post-processing techniques, and securing the platforms from cyber-physical vulnerabilities. The system is installed as a showcase piece in a newly created multidisciplinary educational and research space dedicated to preparing undergraduate and graduate students for future careers in Industry 4.0 technologies. As such, the new system will enable multi-disciplinary research and education across the entire value chain of AM.