Development of Large-Class 3D Printing by means of ?VARIOCLAD? Laser Metal Deposition
Programme
GSTP
Programme Reference
GT27-018MS
Prime Contractor
Laser Cladding Venture NV
Start Date
End Date
Status
Closed
Country
Belgium
Objectives
This activity intends to extend the capabilities of existing Laser Metal Deposition (LMD) systems such that not only large dimensions, but also high accuracy can be achieved.
Description
Additive Manufacturing is a key-enabling technology for space products. For launch vehicles as well as spacecraft, a variety of parts has the potential to be optimised and produced through Additive Manufacturing, leading to significant performance increases. This includes parts ranging from a few millimeters like harness clips up to optical benches with dimensions of several meters.
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At this point in time, there is no manufacturing technique that offers sub-millimeter resolution and build envelopes of meters. As a result, large parts can either be produced at once and be machined afterwards to achieve the required accuracy and fidelity, or the large parts would be made of several smaller ones with higher accuracy and joined through welding, bolting, or brazing afterwards. Both solutions have disadvantages from an economical and / or a technical point of view.
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This activity intends to extend the capabilities of existing Laser Metal Deposition (LMD) systems such that not only large dimensions, but also high accuracy can be achieved. The activity will consist of the following steps:
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- Increase of resolution through enhanced laser cladding heads with capability to modulate both the focus range, the focus area and the powder feed rate.
- Enhancement of free-form capabilities through the development of supporting structures for LMD processes
- Optimisation of productivity and breadboarding, by applying the above developed concepts.
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Four key technical challenges will be addressed during the activity:
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- Thermal stresses due to thermal gradients which affect shape stability and geometric resolution
- Deposition stability due to de-focussed printing which again originate from either uncontrolled heat input or deformation effects
- Deposition effectivity due to material overshoot which originate from partial melting of the feedstock
;;;;;;- Freeform limitations due to absence of a support strategy
Application Domain
Generic Technologies
Technology Domain
24 - Materials and Manufacturing Processes
Competence Domain
2-Structures, Mechanisms, Materials, Thermal
Initial TRL
TRL 2
Target TRL
TRL 4
Achieved TRL
TRL N/A