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Unlocking the potential of laser 3D printing with ultrasound

Project description

Sound and light come together in advanced 3D printing of high-performance metals

Additive manufacturing, also called 3D printing, in which materials are deposited in a bottom-up fashion rather than conventional cutting and shaping methods, offers many advantages for the production of metal components. However, it faces challenges in the control of the alloy’s microstructure, leading to inconsistent mechanical properties, including fatigue life and tensile strength. Within the last few years, the application of ultrasound has shown potential to control fine grain structure and minimise this critical issue. The EU-funded Ultra3DPrint project will employ advanced modelling and synchrotron x-ray imaging techniques to fully characterise the laser 3D printing of metals assisted by ultrasound. Deeper understanding should lead to greater control and defect-free components.


If successful, this project will be a milestone in the development of 3D printing of metals by laser-directed energy deposition. The purpose of this project is to establish a scientific understanding of laser 3D printing of metals under the influence of ultrasound. A full description of this process will ensure the consistent performance of printed products for critical applications. The applicant will combine cutting-edge in situ synchrotron x-ray imaging and modelling approaches to characterise the development of the melt pool. Expected outcomes are likely to provide production guidance on laser 3D printing of metals with defect-free, highly refined grain structures that can be used to produce high value-added products. This research fellowship will enable the applicant to become an independent research group leader in the field of laser 3D printing.


Net EU contribution
€ 212 933,76
WC1E 6BT London
United Kingdom

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London Inner London — West Camden and City of London
Activity type
Higher or Secondary Education Establishments
Total cost
€ 212 933,76