Additive manufacturing (AM) is a fast-growing sector with the
ability to evoke a revolution in manufacturing due to its almost
unlimited design freedom and its capability to produce personalised
parts locally and with efficient material use. AM companies,
however, still face technological challenges such as limited
precision due to shrinkage, built-in stresses and limited process
stability and robustness. Moreover, often post-processing is needed
due to high roughness and remaining porosity. Qualified, trained
personnel are also in short supply. In recent years, there have
been dramatic improvements in AM design methods, process control,
post-processing, material properties and material range. However,
if AM is going to gain a significant market share, it must be
developed into a true precision manufacturing method. The
production of precision parts relies on three principles:
Production is robust (i.e. all sensitive parameters can be
controlled). Production is predictable (for example, the shrinkage
that occurs is acceptable because it can be predicted and
compensated in the design). Parts are measurable (as without
metrology, accuracy, repeatability and quality assurance cannot be
known). AM of metals is inherently a high-energy process with many
sensitive and inter-related process parameters, making it
susceptible to thermal distortions, defects and process drift. The
complete modelling of these processes is beyond current
computational power, and novel methods are needed to practicably
predict performance and inform design. In addition, metal AM
produces highly textured surfaces and complex surface features that
stretch the limits of contemporary metrology. With so many factors
to consider, there is a significant shortage of background material
on how to inject precision into AM processes. Shortage in such
material is an important barrier for a wider uptake of advanced
manufacturing technologies, and a comprehensive book is thus
needed. This book aims to inform the reader how to improve the
precision of metal AM processes by tackling the three principles of
robustness, predictability and metrology, and by developing
computer-aided engineering methods that empower rather than limit
AM design. Richard Leach is a professor in metrology at the
University of Nottingham and heads up the Manufacturing Metrology
Team. Prior to this position, he was at the National Physical
Laboratory from 1990 to 2014. His primary love is instrument
building, from concept to final installation, and his current
interests are the dimensional measurement of precision and additive
manufactured structures. His research themes include the
measurement of surface topography, the development of methods for
measuring 3D structures, the development of methods for controlling
large surfaces to high resolution in industrial applications and
the traceability of X-ray computed tomography. He is a leader of
several professional societies and a visiting professor at
Loughborough University and the Harbin Institute of Technology.
Simone Carmignato is a professor in manufacturing engineering at
the University of Padua. His main research activities are in the
areas of precision manufacturing, dimensional metrology and
industrial computed tomography. He is the author of books and
hundreds of scientific papers, and he is an active member of
leading technical and scientific societies. He has been chairman,
organiser and keynote speaker for several international
conferences, and received national and international awards,
including the Taylor Medal from CIRP, the International Academy for
Production Engineering.
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