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Design Of Lightweight, High Stiffness, And Low Strength Parts Using Metallic Skins For Large Format Additive Manufacturing Processes


Title: Design Of Lightweight, High Stiffness, And Low Strength Parts Using Metallic Skins For Large Format Additive Manufacturing Processes

Authors: Emily N. Piatt, Vysakh Venugopal, Sam Anand

DOI: 10.33599/nasampe/c.23.0025

Abstract: Large-format additive manufacturing (LFAM) has yielded success in the tooling industry with its ability to create complex and unique parts with low material costs. However, there is a growing demand for the creation of end-use parts using LFAM. Current methods fail to allow LFAM to produce parts with a high stiffness-to-weight ratio due to the density of the printed parts required to meet the structural requirements of the applications. This paper seeks to expand the use of printed components by determining the viability of applying metallic skins to a printed part. This method allows for the printing of structural components; and expands the use of LFAM to stiffness-limited applications. The metallic skinning method proposed in this paper involves creating a lightweight 3D printed structure and bonding sheet metal to its surfaces to stiffen the printed part without significantly increasing part cost or weight. Currently, high-stiffness printed parts use high-temperature thermoplastics or other custom material blends. These materials are denser and less cost-effective than their lower-temperature counterparts, making them unsuitable for many production parts. The proposed method's viability is validated through a use case replacing a CNC gantry honeycomb structure with a 3D-printed part. Finite Element Analysis results from this study showed that the proposed method could closely match or slightly improve upon the weight, stress, and deflection of the original honeycomb structure. It also reduced the stress and deflection compared to only the 3D-printed part by over 80 percent and 90 percent, respectively. This method of metallic skinning will allow LFAM to expand its influence into more applications, including aerospace parts and CNC gantries, while significantly reducing cost and lead times from methods such as aluminum honeycomb. Future expansions on this research would be to further reduce the overall weight of the printed parts by developing topology optimization and lattice structure methods specific to LFAM.

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Conference: CAMX 2023

Publication Date: 2023/10/30

SKU: TP23-0000000025

Pages: 16

Price: $32.00

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