Abstract
Direct fabrication technology, which utilizes computer-aided design solid models to automatically control the manufacture of functional piece parts, is rapidly gaining popularity as a means to significantly reduce the time to market of new concepts. Since the introduction of stereolithography in 1982, several different rapid prototyping technologies have evolved using surrogate rather than actual materials of construction. Most recently, researchers have begun to develop laser-based methods to obtain fully dense metallic components directly from a computer-aided design solid model. Each of these methods is unique, but possesses aspects that are similar to the others. Many of these methods hold a great deal of promise for applications; however, none have been developed into a commercial product.
Similar content being viewed by others
References
M.L. Murphy, W.M. Steen, and C. LeeA Novel Rapid Prototyping Technique for the Manufacture of Metallic Components, (Orlando, FL: CALEO, 1994), p. 31.
H.L. Marcus, ed.,Proceedings from Solid Freeform Fabrication Symposia, (Austin, TX: University of Texas, 1990–1996).
C. Hull, “Apparatus for Production of Three-Dimensional Objects by Stereolithography,” U.S. patent 4,575,330 (11 March 1986).
R. Jamieson and H. Hacker,Direct Slicing of CAD Models for Rapid Prototyping (MCB University Press, 1995).
C.O. Brown, E.M. Breinan, and B.H. Kear, “Method for Fabricating Articles by Sequential Layer Deposition,” U.S patent 4,323,756 (6 April, 1982).
D.M. Keicher et al., “Laser Engineered Net Shaping (LENSTM) for Additive Component Processing” (Paper presented at the 1996 SME Conference, Dearborn, MI, 1996).
G.K. Lewis et al.,Directed Light Fabrication, LANL publication LA-UR-95-2845 (1995).
S. Carty et al., “Multi-Directional Laser Surface Cladding in any Orientation,”ICALEO 1995, (Orlando, FL: ICALEO 1995), p. 467.
J.L. Koch and J. Mazumder, “Rapid Prototyping by Laser Cladding,”ICALEO 1993 (Orlando, FL: ICALEO 1993), p. 556.
D.M. Keicher et al.,Towards a Reliable Laser Spray Powder Deposition System Through Process Characterization, Albuquerque, NM: SAMPE, 1995), p. 1009.
D.M. Keicher, J.E. Smugeresky, and J.A. Romero et al., unpublished work, 1996.
F.G. Arcella, E.J. Whitney, and D. Krantz, “Laser Forming Near Shapes in Titanium,”ICALEO 1995 (Orlando, FL: ICALEO, 1995), p. 178.
D.M. Keicher et al., “Free Form Fabrication Using the Laser Engineered Net Shaping (LENSTM) Process” (Paper presented at 1996 PM2TEC, Washington, D.C., 1996)
A. Christiana et al., “Materials Issues in Layered Forming,”Proc. Solid Freeform Fabrication Symposium (Austin, TX: U. of Texas, 1993).
R. Merz et al., “Shape Deposition Manufacturing,”Proc. Solid Freeform Fabrication Symposium (Austin, TX: U of Texas, 1994).
K. Hartman et al., “Robot-Assisted Shape Deposition Manufacturing,”Proc. 1994 IEEE Int. Conf. O Robotics and Automation (New York: IEEE, 1994).
M.L. Griffith et al. “Free Form Fabrication Of Metallic Components Using Laser Engineered Net Shaping (LENSTM),”Proc. Solid Freeform Fabrication Symposium 1996, (Austin, TX: U. of Texas, 1996).
G.M. Fadel and C. Kirschman,Accuracy Issues in CAD to RP TranslationS (MCB University Press, 1995).
G.K. Lewis et al. “Directed Light Fabrication,”ICALEO 1994, (Orlando, FL: CALEO, 1994), p. 17.
G.K. Lewis et al., (Paper presented at 1996 PM2TEC, Washington, D.C., 1996).
R. Olsen, private communication (1996).
L.P. Schanwald, “Two Powder Stream Diagnostics for Laser Deposition Processes,”ICALEO 1995 (Orlando, FL: ICALEO, 1995), p. 660.
D.D. Voelkel and J. Mazumder, “Visualization and Dimensional Measurement of the Laser Weld Pool,”ICALEO 1990 (Orlando, FL: ICALEO, 1990), p. 422.
U.S. Navy, “Method and Apparatus for Noncontact Surface Contour Measurement,” U.S. patent 5,446,549 (29 August 1995).
DARPA funded work.
Protosynthesis, “Method of 3-Dimensional Rapid Prototyping through Controlled Layerwise Deposition/Extraction and Apparatus,” US. patent 5398193 (14 March, 1995).
Additional information
D.M. Keicher earned his M.Sc. in electrical engineering from the University of New Mexico in 1994. He is currently vice president of direct metal deposition at Optomec Design Company.
J.E. Smugeresky earned his Ph.D. in materials science and engineering at the University of Pennsylvania in 1969. He is currently a senior member of the technical staff at Sandia National Laboratories. Dr. Smugeresky is also a member of TMS.
Rights and permissions
About this article
Cite this article
Keicher, D.M., Smugeresky, J.E. The laser forming of metallic components using particulate materials. JOM 49, 51–54 (1997). https://doi.org/10.1007/BF02914686
Issue Date:
DOI: https://doi.org/10.1007/BF02914686