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Metal Powder-based Additive Manufacturing

Wednesday 10th October - Theatre 9 - Lounge South

The aim of this meeting which is dedicated to Additive Manufacturing (AM), is to provide a platform for technical discussion of areas related to metal powder based AM processes and to encourage better communication and co-operation between leading and upcoming academics and industrialists in the field - MORE>


09:00 Registration opens in the atrium
10:15 Welcome and opening remarks

Session 1

  Chair: David Brackett / Ian Maskery
10:20 Laser powder bed fusion in sub-atmospheric and high-pressure atmospheres
Professor Andrew Moore, Heriot-Watt University, UK

An open-architecture laser powder bed fusion (PBF) system was used for high-speed imaging of the dynamics of the process under different pressures and atmospheres. Experiments were carried out under sub-atmospheric, atmospheric and high-pressure conditions, and in argon and helium atmospheres. Long standoff microscopy results showed the motion of particles in the powder bed and schlieren imaging visualised the fluid dynamics of the inert atmosphere. Multiphysics modelling, validated by the experiments, was carried out to understand the complex interactions between laser, metal powder and inert gas. These results provide useful information for process planning, including on powder denudation, dynamic packing density, the production of metal vapour and spatter, and variations in laser absorption into the powder bed.

10:50 Heat treatment of metal additive parts – are conventional treatments enough?
Nick Cruchley, Manufacturing Technology Centre, UK

There are a wide range of heat treatments available for controlling the properties of metal additive materials, many of the heat treatments utilise conventional treatments designed for cast and wrought material. The academic literature has begun exploring whether these treatments are sufficient for optimising the properties. This talk will examine the effectiveness of conventional treatments and evaluate opportunities in obtaining better properties through emerging treatments. The emergence of hot isostatic pressing as a necessary treatment step for critical applications has garnered support recently and its effects on additive materials will be considered.

11:10 Process simulation for laser powder bed fusion
Wolfgang Otto, ESI, Germany

Modelling powder bed fusion processes involves resolution of several interacting physical phenomena. Laser irradiation is a key phenomenon driving powder heat up, melting and the solidification of consolidated material. The thermal history of the work piece is usually complex both in space and time. The material shrinkage and clamping devices lead to residual stresses that affect the final workpiece shape. The final workpiece properties, the accumulated residual stresses and the overall distortions are complex functions of the input parameters: Powder and heat.
Within this presentation a multiscale/multiphysics process simulation approach is highlighted. Both, macroscopic manufacturability assessment as well as microscopic material quality are tackled in this approach. Powder spreading, laser heat source absorption and material phase changes (melting and solidification) are simulated to identify defects related to those processes. In addition, residual stress and distortion predictions are shown.

11:30 In room break
12:00 Powder bed manufacturing-the next generation machine
Derrick Jepson, Aerotech Ltd., UK

'Bells and whistles have continually been added to machines to make the job easier e.g. digital readouts, automated in-feeds etc. However, true fundamental capability improvements are what has driven the machine tool industry into such diverse and profitable markets, chief among these would be 5 and 7 axes of coordinated motion and the ability to rapidly change and utilise a wide array of tool types.

Perhaps the most important though has been the development of an in-depth understanding of the material processing interactions that dictate things like surface finish and geometrical accuracy, arguably these are the developments that have truly pushed the machine tool industry to where it is today.

Although we view these capabilities as crucial and enabling, they are just the beginning.

Aerotech sees a future where powder-bed additive machines are extraordinarily versatile and capable of true precision in their own way, eventually we believe that the user will be capable of purposefully and independenty control all of the process parameters that influence part quality in a sintering based AM machine.'

Bonnie Attard, University of Birmingham
Vicente Rivas Santos, University of Nottingham
David Pervan, University of Nottingham
Alexander Gasper, University of Nottingham
13:10 Break
  Session 2
  Chair: David Brackett / Ian Maskery
14:25 Welcome back
14:30 Opportunities in metal additive manufacturing beyond structural materials
Professor Moataz Attallah, University of Birmingham, UK

The talks an overview of the research activities of the Advanced Materials & Processing Lab (AMPLab) in the field of Additive Manufacturing (AM) using powder bed fusion (PBF), focusing on the applications to functional materials (shape memory alloys, soft magnetic materials, nuclear materials, and biomedical materials). In particular, the talk will explore the use of PBF to produce magnetic shielding structures for quantum metrology applications, customised peripheral stents using smart materials, refractory metals for fusion reactors, and low-modulus titanium alloys for medical implants.  The talk also summarises the key metallurgical challenges that face the development and deployment of AM technologies for these specific applications.

14:50 A practical guide to procuring AM components
Adam Scott, SST Technology Ltd, UK

This presentation intends to walk the audience through the process of procuring a component created by AM working with SST Technology. From the customer’s point of view, they want a finished part that meets their requirements/specification.  Different customers will have different specifications and some have none at all.  On one hand, if a part can be made to conform to a drawing and serves its function, the customer is happy.  On the opposite end of the spectrum, the customer could specify everything to do with the entire job including things like the laser parameters and powder feedstock requirements.  Coming up with a sensible specification and practically producing parts consistently with AM is a great challenge.  (Powder bed) AM is not as well understood as subtractive machining; to achieve a desired surface finish or a specific positional accuracy, extra material must be added to AM components to allow a machining operation.  The process of taking in a set of customer requirements to physically producing a component will be explored from two perspectives, one using SST Technology as a service provider in a ‘build to print’ capacity and one using it as a ‘development partner’; the aim being to demonstrate the value in working with SST (and AM suppliers generally) rather than simply ‘using’ them.  Throughout the presentation, the (software/simulation) tools (for process simulation and part optimisation) used will be described and their value in the overall process highlighted.

15:10 Digital Metal®- Fast, reliable AM technology for production of high precision metal components.
Hans Kimblad, Digital Metal, Höganäs AB, Sweden

Digital Metal® is a unique, high-precision binder-jetting AM technology developed by Höganäs AB. Offering high print speed and cost-effective production of customised parts. Up till now, Digital Metal has helped its customers manufacture more than 300,000 high-quality components.

15:30 Break in the exhibition hall -
15:50 ENCOMPASS project-Pulsed laser AM
Sam Evans, University of Liverpool, UK

This work forms part of the EU Horizon 2020 research and innovation programme ENCOMPASS to develop an Integrated Design Decision Support System (IDDS) to cover the whole manufacturing chain for a laser powder bed fusion (L-PBF) process end-to-end. As part of this programme a study has been conducted on the use of next generation industrially robust ns pulsed fibre lasers for the L-PBF AM process. We report on the initial results of trials conducted at the University of Liverpool on Renishaw systems and provide brief overview of the larger ENCOMPASS project.

16:10 Qualifying powder feedstock requirements for additive manufacturing processes
Dr. Steven Hall, Senior Research Engineer, Materials Engineering, Manufacturing Technology Centre, UK

Manufacturing of complex metal parts by additive manufacturing is becoming more widespread as it offers greater design flexibility and reduced waste compared with traditional manufacturing processes.

For powder based processes the quality of the raw metal powder is process critical in terms of the packing behaviour and flow characteristics of the powder. This can influence manufacturing efficiency and both the integrity and quality of the finished part.

In this presentation we will show why powder characteristics are so critical for additive manufacturing and how these characteristics can be measured and controlled for optimum packing and processability.

16:30 Precious Metal Additive Manufacturing: Opportunities and Challenges
David Fletcher, Cookson Gold
16:50 -close of meeting-
17:15 Coach departs for visit to MTC.


Tour of The National Centre for Additive Manufacturing

After the conclusion of the technical programme and exhibition there is the offer of a tour of the National Centre for Additive Manufacturing at the Manufacturing Technology Centre. Challenging the boundaries of manufacturing: The Manufacturing Technology Centre (MTC) develops and proves innovative manufacturing processes, including laser based Additive Manufacturing, and operates some of the most advanced manufacturing equipment in the world -

The opportunity includes: - Free Coach to and from Ricoh Arena | Tour of National Centre for Additive Manufacturing at the MTC | Buffet meal.

The tour will last approximately an hour and a buffet meal will follow. Departures back to the Ricoh Arena will be at approximately 19.30.

The MTC operates a strict security policy. To register your attendance onto the tour, please send the following information to by Monday 8 October 2018:

  • Your full name
  • Job title
  • Company name
  • Nationality
  • Special dietary requirements

Please bring a valid form of photographic ID with you (British nationals – driving licence/ foreign nationals – passport). The coach will pick up on Judds Lane a short distance on the left after the roundabout.

Please note that if you haven’t pre-registered by 8 October 2018 or come without valid ID, you will not be granted access onto the tour.

If you are a Russian or Chinese national, permission for access into the main MTC building can only be granted by the Ministry of Defence. This process takes a minimum of 21 working days and therefore must be highlighted at the earliest opportunity. Where a minimum of 21 days’ notice is not given for Russian or Chinese nationals, access will be denied.

What to do next

■ Send this information to your colleagues and associates who may be interested
■ Register to attend

Aerotech’s Infinite Field of View Solves the Spot Size Versus Field of View Conundrum

Technical challenges abound in the pursuit of quality parts from additive manufacturing powder-bed processes. Many of these challenges are interdependent and therefore compromises are frequently made that result in an additive machine with mediocre resolution and less than desirable build volume.

Aerotech's technology and expertise eliminate these compromises, giving OEM and end-user machine builders the ability to increase field of view, limit variations in energy/power density, control laser pulses as a function of position, maximize yield, and eliminate thermal instability.

Continue reading>



European Industry Assocation partner



Dr David Brackett (Co-chair)
The Manufacturing Technology Centre (MTC)

Dr Ian Maskery (Co-chair)

University of Nottingham


Dr Wessel W. Wits
University of Twente

Dr Alessandro Fortunato
University of Bologna

Dr David Brackett
Manufacturing Technology Centre

Dr Adam Clare

University of Nottingham

Prof. Chris Tuck
University of Nottingham