Manufacturing Decision Tree Model Optimization for Finishing Additive Manufactured Components

This Phase I program addresses the challenge of gaining the necessary knowledge needed to support certification of additive manufacturing (AM) hardware and achieving the desired surface finish and mechanical properties on high value components produced by AM. To achieve this goal Faraday Technology Inc., will work with team members at UES Inc., CalRAM Inc., Keystone Synergistic Enterprise Inc., and REM Surface Engineering to develop the necessary empirical knowledge to produce a manufacturing decision tree model (MDTM) that will enable the part designer to reduce the cycle time required produce the desired part with the required surface finish. The MDTM will be designed to select the appropriate build pathway to form the desired component and improve the as-built surface finish on the required areas while also determining the necessary secondary steps to achieve the desired surface finish on all required surfaces. With this teams combined expertise range from AM part building [ARCAM (E-BEAM), SLM (LASER), Wire Fed (E-BEAM)], secondary AM part finishing [electrochemical and isotropic], and post process AM material evaluation (tensile and microstructural characterization) we will be able to diagnose the best manufacturing cycle to reduce time and cost while ensuring the functionality of the produced material is maintained through each processing step. It is envisioned that the outcome of this Phase I/II program would be a working MDTM that has the potential to diagnose the best manufacturing pathway to produce a wide range of high-value components with various shapes and contours.