Rapid Manufacturing Research at the Catholic University of Leuven

Abstract

Additive layer manufacturing (LM) is commonly used for manufacturing prototypes (RP), tools (RT) and functional end products (RM) in a wide range of industries including medicine, automotive and aerospace industries. One of the key advantages of RM over conventional machining is the elimination of molds, dies, and other forms of tooling, and the consequent eradication of tooling restrictions. Moreover, almost infinite geometrical complexity, mass customization, individualization and material flexibility give RM other superior properties. For RM to prosper, the limitations of existing additive processes must be overcome, e.g. limitations such as repeatability, reliability, surface finish, material properties and productivity. At the University of Leuven, selective laser melting/sintering (SLM/SLS) of metals, ceramics and polymers is studied aiming to develop the process to a level enabling RM of complex and customized parts in a competitive way. In order to achieve this overall goal, a monitoring and control system of SLM/SLS for metals is installed in an in-house developed machine to process metals. Laser re-melting and selective laser erosion (SLE) are employed during or after SLM/SLS in order to improve surface quality and density as well as to modify the microstructure and mechanical properties. For medical applications, design and manufacturing of scaffolds and dental prostheses with required mechanical properties are conducted including the investigation of the influence of structural parameters (porosity, cell size and cell shape) on the cell growth. In order to widen the palette of applicable materials, K.U.Leuven does not only focus on metallic materials, but also on direct or indirect SLM of ceramics as well as machine modifications such as pre-heating modules and deposition systems necessary to handle ceramics.status: publishe