Unlocking the potential of laser 3D printing with ultrasound

Project Information

Ultra3DPrint

Grant agreement ID: 101023970

DOI

10.3030/101023970

Project terminated on 25 February 2023

EC signature date 1 March 2021

Start date 1 September 2022

End date 31 August 2024

Funded under

• EXCELLENT SCIENCE - Marie Skłodowska-Curie Actions

Total cost

€ 212 933,76

EU contribution

€ 212 933,76

Coordinated by

UNIVERSITY COLLEGE LONDON
United Kingdom

Periodic Reporting for period 1 - Ultra3DPrint (Unlocking the potential of laser 3D printing with ultrasound)

Reporting period: 2022-09-01 to 2024-08-31

Summary of the context and overall objectives of the project

A key barrier to metal 3D printing in the industry is the large crystals and voids that occur in most printed products, affecting their serviceability. Recently, a method of introducing high-frequency sound waves into metal products during printing has shown promise to control the formation of crystals and voids. This research will employ advanced modelling and synchrotron x-ray imaging techniques to fully understand the 3D printing of metals assisted by sound waves. Such an understanding would help to position 3D printing as a competitive technology to produce high-quality and reliable metal products.

Work performed from the beginning of the project to the end of the period covered by the report and main results achieved so far

The fellow has designed bespoke ultrasound equipment for implementation into an x-ray imaging system for in situ x-ray imaging of the melt pool in ultrasound-assisted laser 3D printing. The fellow has outsourced the manufacturing of the ultrasound system to a German-based company Sonic Power GmbH CO & KG.

Progress beyond the state of the art and expected potential impact (including the socio-economic impact and the wider societal implications of the project so far)

A competitive manufacturing sector in the European Union (EU) is vital for job creation and economic growth in the region. However, low-cost developing countries are challenging the competitiveness of EU manufacturing industries. The European Commission (EC) has identified 3D printing as a Key Enabling Technology that is expected to produce high-value-added products across all major industrial sectors, including aeronautics, automotive, biomedical, construction, space, and many others. Further, the EC has deemed that 3D printing is likely to create skilled jobs and local manufacturing, presenting an opportunity to bring outsourcing jobs back to Europe.

Overall view of the experimental setup and the analyses method.