Article In: orcid, scopus

Enhancing the Performance of Laser Powder Bed Fusion Through Hybridization with Bending

International Journal of Lightweight Materials and Manufacture

Cristino V.A.M.; Sampaio R.F.; Carlos M.A. Silva — 2025

Key information

Authors:

Cristino V.A.M.; Sampaio R.F. (Rui Filipe Vieira Sampaio); Pragana J.P.M. (João Pedro da Fonseca Matos Pragana); Bragança I.M.F. (Ivo Manuel Ferreira de Bragança); Silva C.M.A.; Martins P.A.F. (Paulo António Firme Martins); Valentino A.M. Cristino (Valentino Anok Melo Cristino); Carlos M.A. Silva (Carlos Manuel Alves da Silva)

Published in

May 1, 2025

Abstract

This paper is focused on the hybridization of metal additive manufacturing with bending to shape thin-walled deposited materials into fully three-dimensional custom parts with specific angles. The presentation covers material deposition by laser powder bed fusion, material and formability characterization using tension and three-point bending tests, and proof-of-concept validation through bending a flat, cross-shaped, deposited plate into a slender three-dimensional double U-shaped part. The use of digital image correlation and finite element analysis supports the presentation as well as the design and creation of the part. Results underscore the significance of hybridizing metal additive manufacturing with bending due to the gains obtained in material usage and fabrication time of 87.9 % and 85.7 %, respectively. The overall methodology integrating material deposition, formability analysis, and combined experimental and finite element simulation of bending proves effective for designing hybrid metal additive-manufactured parts, providing a comprehensive framework for future research and development in this area.

Publication details

Authors in the community:

Title of the publication container

International Journal of Lightweight Materials and Manufacture

First page or article number

301

Last page

309

Volume

8

Issue

3

DOI

10.1016/j.ijlmm.2024.12.003

Fields of Science and Technology (FOS)

mechanical-engineering - Mechanical engineering

Keywords

  • Hybrid additive manufacturing
  • Laser powder bed fusion
  • Bending
  • Formability
  • Finite element method
  • Experimentation

Publication language (ISO code)

eng - English

Rights type:

Only metadata available

Financing entity

Fundação para a Ciência e a Tecnologia

Funding Stream: LAETA Base Funding

Number for the project, award or grant: UIDB/50022/2020