A NEW MULTI-MATERIAL DIRECT LASER SINTERING PROCESS FOR ADVANCED MATERIALS DESIGN APPROACHES

This work proposes a new Multi-Material Direct Laser Sintering/Melting additive process (MMDLS/M) for the production of Multi Material components with materials gradations Functionally Graded Materials (MMFGMs). An additive layer-by-layer process was used, which is ideal for MMFGMs, since by design, material is only added where is strictly and functionally needed, minimizing waste and enhancing the overall properties of the component being built and theoretically imposes no restriction on the shape being built, being highly customizable, which makes it ideal for applications in many industries such as medical, aeronautical, etc. Moreover, this process encompasses a wider perspective of the global methodology of a component’s production, since the physical phenomena occurring during these processes have a strong impact on the quality of the produced parts, so special focus has been given to the design and manufacturing stages, with a closed-loop control to apply corrections to the deviations between the model and the printed part. As the technology did not fit the customization and freedom requirements associated with this process, an equipment was designed and built, recurring to the agile development method.