Available Technologies

In additive manufacturing, choice of process parameters for a given material and geometry can result in porosities in the build volume, which can result in scrap.

Estimates based on the U.S. Department of Energy (DOE) test procedure for water heaters indicate that the equivalent of 350 billion kWh worth of hot water is discarded annually through drains, and a large portion of this energy is, in fact, recoverable.

Distortion generated during additive manufacturing of metallic components affect the build as well as the baseplate geometries. These distortions are significant enough to disqualify components for functional purposes.

For additive manufacturing of large-scale parts, significant distortion can result from residual stresses during deposition and cooling. This can result in part scraps if the final part geometry is not contained in the additively manufactured preform.

In additive manufacturing large stresses are induced in the build plate and part interface. A result of these stresses are deformations in the build plate and final component.

The incorporation of low embodied carbon building materials in the enclosure is increasing the fuel load for fire, increasing the demand for fire/flame retardants.

Materials produced via additive manufacturing, or 3D printing, can experience significant residual stress, distortion and cracking, negatively impacting the manufacturing process.

This work seeks to alter the interface condition through thermal history modification, deposition energy density, and interface surface preparation to prevent interface cracking.

Additive manufacturing (AM) enables the incremental buildup of monolithic components with a variety of materials, and material deposition locations.