Design for Metal Additive Manufacturing: An Investigation of Key Design Application on Electron Beam Melting
Electron beam melting (EBM) is one of the modern additive manufacturing (AM) technologies. In EBM, the electron beam melts metal powder into a fully solid part layer by layer. Since EBM is a new technology, most designers are unaware of the capabilities and the limitations of EBM technology. Also, many engineers are facing many challenges to utilize the technology because of a lack of design rules for the technology. The aim of this study is to identify the capabilities and the limitations of EBM technology in fabrication of small features and overhang structures and develop a design rules that need to be considered by designers and engineers. In order to achieve this objective, a series of experiments are conducted. Several features having varying sizes were designed, fabricated, and evaluated to determine their manufacturability limits. In general, the results showed the capabilities and limitations of the EBM technology in fabrication of the small size features and the overhang structures. In the end, the results of these investigation experiments are used to develop design rules. Also, the results showed the importance of developing design rules for AM technologies in increasing the utilization of these technologies.
 Seepersad, C. C., Govett, T., Kim, K., Lundin, M. and Pinero, D. (2012) ‘A designer’s guide for dimensioning and tolerancing SLS parts’, Proceedings of the Solid Freeform Fabrication Symposium, Austin, TX, pp.921–931.
 Rajit Ranjan, Rutuja Samant and Sam Anand (2015), ‘Design For Manufacturability In Additive Manufacturing Using A Graph Based Approach’, the ASME 2015 International Manufacturing Science and Engineering Conference MSEC2015, June 8-12, North Carolina, USA.
 J. Kranz, D. Herzog, and C. Emmelmann (2015), ‘Design guidelines for laser additive manufacturing of lightweight structures in TiAl6V4’, Journal Of Laser Applications.
 Thomas D. The development of design rules for selective laser melting: University of Wales; 2009.
 Murr LE, Gaytan SM, Ramirez DA, Martinez E, Hernandez J, Amato KN, et al. Metal fabrication by additive manufacturing using laser and electron beam melting technologies. Journal of Materials Science & Technology 2012;28:1-14.
 Calignano F. Design optimization of supports for overhanging structures in aluminum and titanium alloys by selective laser melting. Materials & Design 2014;64:203-13.
 Ö. Poyraz* EY, G. Akbulut*, A. Orhangül*, S. Pilatin*. Investigation Of Support Structures For Direct Metal Laser Sintering (Dmls) Of In625 Parts. International Solid Freeform Fabrication Symposium. Austin, Texas, USA2015.
 Abe F, Osakada K, Shiomi M, Uematsu K, Matsumoto M. The manufacturing of hard tools from metallic powders by selective laser melting. Journal of materials processing technology 2001;111:210-3.
 Cormier D, Harrysson O, West H. Characterization of H13 steel produced via electron beam melting. Rapid Prototyping Journal 2004;10:35-41.
 Murr L, Esquivel E, Quinones S, Gaytan S, Lopez M, Martinez E, et al. Microstructures and mechanical properties of electron beam-rapid manufactured Ti–6Al–4V biomedical prototypes compared to wrought Ti–6Al–4V. Materials characterization 2009;60:96-105.
 Vayre B, Vignat F, Villeneuve F. Identification on some design key parameters for additive manufacturing: application on electron beam melting. Procedia CIRP 2013;7:264-9.
 Vora P, Derguti F, Mumtaz K, Todd I, Hopkinson N. Investigating a Semi-Solid Processing Technique Using Metal Powder Bed Additive Manufacturing Processes. 24th Annual International Solid Freeform Fabrication Symposium-An Additive Manufacturing Conference, Austin, TX, USA2013.
 RamiTOUNSI FV. New concept of support structures in Electron Beam Melting manufacturing to reduce geomtricdefects. 15e Colloque National AIP-Priméca2017.
 Ameen, Wadea, Abdulrahman Al-Ahmari, Muneer Khan Mohammed, and Syed Hammad Mian. (2018). "Manufacturability of Overhanging Holes Using Electron Beam Melting." Metals (2075-4701) 8, no. 6.
 Ö. Poyraz*, E. Y., G. Akbulut*, A. Orhangül*, S. Pilatin*. Investigation Of Support Structures For Direct Metal Laser Sintering (DMLS) OF IN625 PARTS. in International Solid Freeform Fabrication Symposium. 2015. Austin, Texas, USA.