METHODS OF AUTOMATING THE LASER-FOIL-PRINTING ADDITIVE MANUFACTURING PROCESS

Laser Foil Printing (LFP) is a laser-based metal Additive Manufacturing (AM) method recently developed at Missouri University of Science and Technology. This study investigates and compares two different methods of automating part fabrication for the LFP process. Specifically, the edge elevation issue due to laser cutting is investigated. Edge elevation occurs after the foil cutting operation, which is an essential step of the LFP process. Previously, mechanical polishing was done to remove the elevated edges for the fabrication of each layer. However, as mechanical polishing is very time-consuming, the current study focuses on two other methods to eliminate the elevated edges. One of them uses laser polishing to remove the elevated edges. Another method is changing the order of the fabrication steps between pattern welding and contour cutting in the LFP process. Comparisons are made to observe the differences in part quality, properties, and building time between these two methods.