The service conditions of many structural frames composed of tubular metal components would
ideally warrant the use of high strength-to-weight ratio components with shapes and internal
geometries that respond to context-specific structural requirements. Commercially available and
emerging solid freeform fabrication technologies can be utilized to indirectly or directly
manufacture metal tubular structural components with optimizing features that cannot otherwise
be manufactured. The results of prototyping experiments demonstrating the viability and
potential of this application of additive manufacturing will be presented. This presentation will
discuss successful prototype 356 aluminum and 316 stainless steel internally reinforced freeform
tubular components manufactured indirectly using expendable patterns made by selective laser
sintering and 3D printing. The application of laser and metal powder based freeform fabrication
technologies that provide superior material properties will also be discussed, especially in terms
of requirements for multi-axis deposition and sophisticated path planning software, and the
implications of voxel- or layer-based functionally gradient materials.Mechanical Engineerin
