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Automated Simulation Of Selective Laser Melting Additive Manufacturing For Process Design

Award Information
Agency: Department of Energy
Branch: N/A
Contract: DE-SC0011327
Agency Tracking Number: 217422
Amount: $991,334.00
Phase: Phase II
Program: STTR
Solicitation Topic Code: 02a
Solicitation Number: DE-FOA-0001193
Timeline
Solicitation Year: 2015
Award Year: 2015
Award Start Date (Proposal Award Date): 2015-04-06
Award End Date (Contract End Date): 2017-04-05
Small Business Information
10 Executive Park Dr.
Clifton Park, NY 12065-5630
United States
DUNS: 012076795
HUBZone Owned: No
Woman Owned: No
Socially and Economically Disadvantaged: No
Principal Investigator
 Ottmar Klaas
 Dr.
 (518) 348-1639
 oklaas@simmetrix.com
Business Contact
 Mark Beall
Title: Dr.
Phone: (518) 348-1639
Email: mbeall@simmetrix.com
Research Institution
 Rensselaer Polytechnic Institute
 Antoinette Maniatty
 
100 8th St.
Troy, NY 12180-3590
United States

 (518) 276-6984
 Nonprofit College or University
Abstract

Additive Manufacturing (AM), where three-dimensional (3D) objects are created from a digital model by depositing and fusing successive layers of material, provides the ability to produce low-volume, customized products with complex geometries relatively quickly at a moderate cost. However, AM processes sometimes fail to produce acceptable parts, due to either geometric in- accuracy (e.g., shrinkage or warping) or unacceptable material properties, and it is not currently possible to determine a priori whether a process will fail or not. This significantly increases the costs associated with using AM. The overall objective is to develop automated simulation tools for modeling AM processes that accurately predict part geometry and state, such as residual stresses, porosity, and microstructural features related to part quality, for given AM processing conditions, with a focus on Selective Laser Melting (SLM). Such a simulation capability would allow AM system developers and users to try proposed process plans in simulation first. We also plan to develop inverse methods and control strategies using the simulation tools for process design and control. While the pro- posed project will develop tools for SLM, the basic architecture can be extended to a larger family of AM processes.

Commercial Applications and Other Benefits: This project will produce an advanced simulation system for modeling AM processes that will allow AM equipment manufacturers to produce better systems, increasing the efficiency, and reducing the cost of AM. The core technologies developed in this project will be general and will be applicable for use with a wide variety of applications, thus providing benefits past AM applications. Simulation is widely used in the design processes of a large number of industries, including aerospace, electronics, energy, biomedical, and consumer goods; the core tools that Simmetrix provides are already advancing industrys ability to perform predictive analysis and design for complex engineering systems in a time- and cost-effective manner.

* Information listed above is at the time of submission. *

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