Rapid manufacturing of components gets research boost

And the world’s first commercial-scale system for the rapid manufacture of these new-generation metal components is now being developed by engineers at the University of Liverpool, in collaboration with MCP (Mining and Chemical Products) and funded by the Engineering and Physical Sciences Research Council (EPSRC). Using selective laser melting (SLM), parts are built layer by layer from fine metal powders using an infrared laser beam to melt the powders into the required structure. Layers can be as thin as 25 microns. Parts so built have a tiny lattice-like structure, similar to scaffolding but with poles twice the diameter of a human hair, making them ultra-light. Because loads are channelled along the poles, the parts can comprise up to 70 per cent air while remaining strong enough to perform. Aircraft parts, for example, could be produced that are over 50 per cent lighter than conventional alternatives. The project is building on previous EPSRC-funded work carried out over the last six years by the University of Liverpool team, which is led by Dr Chris Sutcliffe. The new manufacturing system is due to be in full commercial use this year. The team is already working on a larger version which should be ready for commissioning in around 18 months.