RF Methods in Additive Manufacturing

Selective Laser Melting (SLM) is an iterative process whereby a 3D object is built from a fine powder bed, producing complex parts of near theoretical density. The free-form 3D capability of SLM manufacture is attractive for next-generation passive RF and microwave components (e.g. satellite payloads).

Project Summary: This iCASE project combines the world class expertise of Renishaw in additive manufacturing with Cardiff's Centre for High Frequency Engineering, using radio frequency (RF) techniques for the manufacture of metal parts. A considerable technical challenge for selective laser melting (SLM) of metal components is the high residual stress within a finished part owing to high temperature gradients in its production, a prime reason why the part fails due to deformation or crack formation.

These issues could be alleviated by direct RF heating of the powder bed by inductive means, so the project will investigate this via the design and development of suitable RF applicators, and their incorporation and optimisation into one of Renishaw's commercial SLM systems.