Consortium show how to design metal AM parts

Members of the LIGHT project consortium will share their findings from the two-year project on the design of parts for metal additive manufacturing (AM) later this month.

LIGHT has investigated design freedom and limitations such as the use of novel low-density lattice structures to support overhanging geometries and so prevent deformation during printing.

The consortium has sought to implement and validate CADCAM solutions that facilitate the selective replacement of internal geometries with self-supporting, low-density lattice structures. If these lattice structures can efficiently support internal and external overhanging geometries, new design freedoms can be achieved.

LIGHT tested the capabilities of additive manufacturing technologies to their limits by producing demonstrator parts that were engineered to withstand extreme conditions. These included a crushable earth re-entry capsule designed to protect planetary samples during atmospheric entry, descent and landing designed by Magna Parva, a jet engine thrust nozzle with operating conditions of 500°C designed by HiETA, and an air brake door hinge that must withstand 50kN of force designed by Bloodhound.

The project is supported by Innovate UK, with the free event held at the Bloodhound SSC Technical Centre in Bristol on 26th April.