Material-structure-performance integrated laser-metal additive manufacturing

• Published in: Science (American Association for the Advancement of Science) Vol. 372; no. 6545
• Main Authors: Gu, Dongdong, Shi, Xinyu, Poprawe, Reinhart, Bourell, David L., Setchi, Rossitza, Zhu, Jihong
• Format: Journal Article
• Language: English
• Published: Washington The American Association for the Advancement of Science 28.05.2021
• Subjects: Additive manufacturing; Aerospace Education; Aerospace industry; Aviation; Avionics; Biomimetics; Cellular structure; Coordination; Data management; Decision making; Design; Digitization; Digitizing; Domains; Fabrication; Genomes; Integrals; Integrated approach; Integration; Laser applications; Lasers; Layouts; Learning algorithms; Machine learning; Manufacturing; Material Development; Materials selection; Mathematical analysis; Mechanical properties; Metals; Methodology; Molecular composites; Monitoring; Motor vehicles; Nanocomposites; Optimization; Printing; Standardization; Strategy; Sustainable development; Technological change; Topology; Uniqueness
• ISSN: 0036-8075; 1095-9203; 1095-9203
• DOI: 10.1126/science.abg1487

Laser-based additive manufacturing has the potential to revolutionize how components are designed. Gu et al. suggest moving away from a strategy that designs and builds components in a serial manner for a more wholistic method of optimization for metal parts. The authors summarize several key developments in laser powder bed fusion and directed energy deposition and outline a number of issues that still need to be overcome. A more integrated approach will help to reduce the number of steps required for fabrication and expand the types of structures available for end-use components. Science , abg1487, this issue p. eabg1487 A Review explains that material-structure-performance integration enables high-performance, multifunctional laser-metal additive manufacturing. Laser-metal additive manufacturing capabilities have advanced from single-material printing to multimaterial/multifunctional design and manufacturing. Material-structure-performance integrated additive manufacturing (MSPI-AM) represents a path toward the integral manufacturing of end-use components with innovative structures and multimaterial layouts to meet the increasing demand from industries such as aviation, aerospace, automobile manufacturing, and energy production. We highlight two methodological ideas for MSPI-AM—“the right materials printed in the right positions” and “unique structures printed for unique functions”—to realize major improvements in performance and function. We establish how cross-scale mechanisms to coordinate nano/microscale material development, mesoscale process monitoring, and macroscale structure and performance control can be used proactively to achieve high performance with multifunctionality. MSPI-AM exemplifies the revolution of design and manufacturing strategies for AM and its technological enhancement and sustainable development.