AM can directly produce parts from CAD data of virtually unlimited complexity without the restriction and cost associated with tooling. The new generation of Selective Laser Melting (SLM) machines provides the opportunity to produce high value structural parts which are extremely efficient in terms of material and energy utilisation and specific strength (strength-to-weight ratio).

Moreover, it can process materials known to be highly suited to space applications. By utilising the capabilities of the AM process, space instrumentation assemblies will be packaged in smaller and more efficient configurations. By being lighter than conventional products, they offer significant benefits by reducing launch costs (launch costs currently exceed £20,000 per kg) and increasing functionality within tight mass/space requirements.

The Problem: 

Unfortunately, at present it is not possible to exploit the advantages of AM due to concerns with respect to the integrity of the parts. One of the primary concerns is that every layer must be processed correctly otherwise part integrity is jeopardised. Moreover, before a new manufacturing process or material can be used for demanding space applications, a qualification process must be undertaken.

In this project there are two main deliverables:

• A novel in-process layer monitoring system will be developed. 
• A full component qualification process to enable SLM products to be used for space applications.

Project Collaboration:

CEEAM is funded by the Transport iNet (part of the East Midlands Development Agency) and has the following collaboration of the following teams:

• The Space Research Centre, University of Leicester - As project leads the group provides expertise in space system design and qualification.
• The Mechanics of Materials Group, University of Leicester - Experts in material performance testing.
• The Additive Manufacturing Technology Group, DeMontfort University - Experts in Additive Manufacturing technology
• MTT Group - Experts in Additive Manufacturing technology and SLM machine manufacturers

Conventional Manufacturing methods involve:

Part is machined from a billet of material larger than the component size. Multiple tools  are required to create features and all removed material must be reformed before it can be reused.

Increasing the part complexity may improve component efficiency but ultimately makes it more time consuming and expensive to make.

Additive Manufacturing Involves:

A 3-D model of the part is split into layers by the machine. The machine then deposits a controlled amount of powder into the build chamber and this is used to create layers of the part by fusing powder together with a laser. As each layer of the part is formed more powder is deposited into the chamber until the part is complete.

A single laser can be used to create a complex part and minimal additional tooling is required. Cost is dependant on volume of material used and not the complexity of the part.