Direct Metal Laser Sintering (DMLS) is a rapid prototyping technique that allows for direct and rapid manufacturing of complex components. DMLS is however an intricate process and the quality of the final product is influenced by multiple manufacturing parameters (or DMLS settings) and powder characteristics. The effect which each of these manufacturing parameters and powder characteristics has on the final parts is not well understood and the success of process manufacturing mainly relies on empirical knowledge. Consequently high dimensional deformation and relatively poor mechanical properties are still experienced in many DMLS products, in particular in copper-based laser sintered parts. A need therefore exists to systematically examine the effect of process parameters on the quality of final parts in order to determine the most appropriate manufacturing parameters for specific applications of copper-based laser sintered parts. This document summarises the effect of different process parameters on the quality of Direct Metal 20 laser sintered parts produced with a EOSINT M250 Xtended laser sintering machine from powder consisting of Ni5Cu, Cu15Sn – Cu5Sn and Cu8P – Cu2P material grains. The quality of the sintered parts is defined in terms of the microstructures, porosities and dimensional deformations obtained. The effects of three different geometric sintering strategies currently in standard use namely Solid Skin, Skin Stripes and Skin Chess were examined, and the more appropriate process parameters and scanning technique for the available set-up is presented. / MIng (Mechanical Engineering), North-West University, Potchefstroom Campus, 2015

Direct Metal Laser Sintering (DMLS) is a rapid prototyping technique that allows for direct and rapid manufacturing of complex components. DMLS is however an intricate process and the quality of the final product is influenced by multiple manufacturing parameters (or DMLS settings) and powder characteristics. The effect which each of these manufacturing parameters and powder characteristics has on the final parts is not well understood and the success of process manufacturing mainly relies on empirical knowledge. Consequently high dimensional deformation and relatively poor mechanical properties are still experienced in many DMLS products, in particular in copper-based laser sintered parts. A need therefore exists to systematically examine the effect of process parameters on the quality of final parts in order to determine the most appropriate manufacturing parameters for specific applications of copper-based laser sintered parts. This document summarises the effect of different process parameters on the quality of Direct Metal 20 laser sintered parts produced with a EOSINT M250 Xtended laser sintering machine from powder consisting of Ni5Cu, Cu15Sn – Cu5Sn and Cu8P – Cu2P material grains. The quality of the sintered parts is defined in terms of the microstructures, porosities and dimensional deformations obtained. The effects of three different geometric sintering strategies currently in standard use namely Solid Skin, Skin Stripes and Skin Chess were examined, and the more appropriate process parameters and scanning technique for the available set-up is presented. / MIng (Mechanical Engineering), North-West University, Potchefstroom Campus, 2015

Ti-6Al-4V alloy has been used as biomedical implants for decades because of its superior mechanical properties, good biocompatibility, lack of allergic problems and good corrosion resistance. It is widely used as the tibial components in total knee arthroplastry and hip cup in total hip replacement. However, the mechanical properties of Ti-6Al-4V implant can be deteriorated due to corrosion pits. In the past decades, the rapid developments in additive manufacturing have broadened their applications in biomedical area due to the high geometrical freedom in fabricating patient-friendly implants. However, the high-localized thermal input and fast cooling rate during laser processing usually result in non-equilibrium phase with high residual stress. Therefore, it is necessary to apply proper post-treatments on the as-printed parts to ensure better properties. In this work, various post-treatments (e.g. post-heat treatments, hot isostatic pressing) were applied aim to improve the corrosion behavior of direct metal laser sintered Ti-6Al-4V parts. The effect of post-treatment temperature on the mechanical properties and corrosion behavior were examined experimentally. A discussion on factors influencing corrosion rate was presented, and the corrosion mechanism on the Ti-6Al-4V part in simulated body fluid was proposed. Based on the electrochemical measurement results, enhanced corrosion resistance was observed in the samples after high temperature HIPing at the annealing temperature (α+β region) of 799°C.

Published Article / Rapid Manufacturing (RM) has emerged over the past few years as a potential technology to successfully produce patient-specific implants for maxilla/facial and cranial reconstructive surgeries. However, in the area of spinal implants, customization has not yet come to the forefront and with growing capabilities in both software and manufacturing technologies, these opportunities need to be investigated and developed wherever possible. The possibility of using Computed Tomography (CT) and Rapid Manufacturing (RM) technologies to design and manufacture a customized, patient-specific intervertebral implant, is investigated. Customized implants could aid in the efforts to reduce the risk of implant subsidence, which is a concern with existing standard implants. This article investigates how accurately the geometry of a customized artificial intervertebral disc (CAID) can represent the inverse geometry of a patient's vertebral endplates. The results indicate that the endplates of a customized disc implant can be manufactured to a calculated average error of 0.01mm within a confidence interval of 0.022mm, with 95% confidence, when using Direct Metal Laser Sintering.

Orthodontic brackets undergo resistance during sliding that includes classical friction, binding, and notching. Current bracket systems are hampered by these challenging forces. As a result, the clinician usually needs to apply additional forces to overcome the resistance which increases the risk of root resorption and discomfort for the patient. This study evaluated frictional properties of a novel bracket that had polytetrafluoroethylene (Teflon™) coated rollers in its design. Five types of brackets (n = 10, each), including a passive self-ligating bracket, a traditional ligated bracket, a three-dimensionally printed direct metal laser sintering (DMLS) bracket with and without Teflon™ rollers, and computer numeric controlled (CNC) machine milled bracket with Teflon™ rollers were tested. The peak resistance values were assessed at 0°, 4°, and 8° of tip on a 0.019 x 0.025” arch wire. At 8° of tip, the DMLS and the CNC milled bracket systems, both with Teflon™ rollers, exhibited less friction as compared to the other brackets tested (p

This diploma thesis presents a technology based on the gradual smelting of fine layers of metal powder by using a laser beam. It explains and describes basic terminology related to the Rapid Prototyping technology, its division and practical usage. A part of the thesis is also the fabrication of several prototype parts by Direct Metal Laser Sintering including the economical comparison of their fabrication with other conventional technologies.

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Metal Additive Manufacturing (AM) technologies in particular powder bed fusion processes such as Selective Laser Melting (SLM) and Direct Metal Laser Sintering (DMLS) are capable of producing a fully-dense metal components directly from computer-aided design (CAD) model without the need of tooling. This unique capability offered by metal AM has allowed the manufacture of inter-connected lattice structures from metallic materials for different applications including, medical implants and aerospace lightweight components. Despite the many promising design freedoms, metal AM still faces some major technical and design barriers in building complex structures with overhang geometries. Any overhang geometry which exceeds the minimum allowable build angle must be supported. The function of support structure is to prevent the newly melted layer from curling due to thermal stresses by anchoring it in place. External support structures are usually removed from the part after the build; however, internal support structures are difficult or impossible to remove. These limitations are in contrast to what is perceived by designers as metal AM being able to generate all conceivable geometries. Because support structures consume expensive raw materials, use a considerable amount of laser consolidation energy, there is considerable interest in design optimisation of support structure to minimize the build time, energy, and material consumption. Similarly there is growing demand of developing more advanced and lightweight cellular structures which are self-supporting and manufacturable in wider range of cell sizes and volume fractions using metal AM. The main focuses of this research is to tackle the process limitation in metal AM and promote design freedom through advanced self-supporting and low-density Triply Periodic Minimal Surface (TPMS) cellular structures. Low density uniform, and graded, cellular structures have been developed for metal AM processes. This work presents comprehensive experimental test conducted in SLM and DMLS processes using different TPMS cell topologies and materials. This research has contributed to new knowledge in understanding the manufacturability and mechanical behaviour of TPMS cellular structures with varying cell sizes, orientations and volume fractions. The new support structure method will address the saving of material (via low volume cellular structures and easy removal of powder) and saving of energy (via reduced build-time).

Otto Scheeloch's U.S. Patent No. 134,442 of 1872 describes a unique firearm that uses triangular bullets. The current research effort evaluates the ballistic performance of Otto's disclosure for the very first time. To achieve this goal it was necessary to seek out surviving artifacts and scour the historical record in search of all the parameters needed to meticulously recreate the curious triangular cartridges and the corresponding gun barrel, with its matching twisted triangular bore. Every aspect of the resulting reproduction ammunition was made to be as authentic as possible, including the use of vintage civil war era bullet lead, bullet grease of period recipe, and the correct type of black powder propellant. 3D CAD (SolidWorksTM) was employed in designing the components, while advanced rapid prototyping (FDM & DMLS) techniques and investment casting were used in the physical construction of the ammunition and barrel. The ballistics testing was performed from a shooting rest over a range of 10-feet. Data was obtained for five rounds using a chronograph, paper targets and ballistic gel. The triangular bullets proved to be surprisingly accurate, consistent, and stable in flight. Data was recorded for sectional density, ballistic coefficient, muzzle velocity and energy, group size and penetration.