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Additive Manufacturing Keynote Session

Seven symposia are planned on additive manufacturing (AM) topics at TMS2018. Tying them all together will be the Additive Manufacturing Keynote Session, a high-level overview of the state of additive manufacturing throughout the world and in various industries.

Featured Speakers

Ming Leu, Missouri University of Science and Technology (MUST)
Presentation Title: "Additive Manufacturing Technologies, Applications, Markets and Opportunities"

Commonly known as 3D Printing, Additive Manufacturing (AM) is a suite of computer automated processes to fabricate three-dimensional physical objects layer by layer from CAD models. AM offers significant benefits over conventional manufacturing processes in producing one-of-a-kind parts or small batches, especially for those with geometric and/or material complexities. It holds great promise for the future as a tool-less, light-out manufacturing technology for components and products made of metals, polymers, ceramics and composites. This talk will first give an introduction of AM technologies along with their applications in the aerospace, healthcare, electronics and other industries. Then, markets and market trends on AM equipment, materials and services in the U.S. and abroad will be overviewed. Finally, future AM business and innovation opportunities will be presented.

About the Speaker: Ming C. Leu is the Keith and Pat Bailey Distinguished Professor in the Department of Mechanical and Aerospace Engineering, Missouri University of Science and Technology, where he is also the Director of the Intelligent Systems Center. He founded Missouri S&T’s Center for Aerospace Manufacturing Technologies in 2004 and has been serving as its director until 2016. Prior to joining Missouri S&T, he was a Program Director at the National Science Foundation, 1996-1999, the State Chair Professor in Manufacturing Productivity at the New Jersey Institute of Technology, 1987-1996, and a faculty member at Cornell University. Leu obtained his Ph.D. degree in 1981 from the University of California at Berkeley, his M.S. degree in 1977 from the Pennsylvania State University, and his B.S. degree in 1972 from the National Taiwan University, all in Mechanical Engineering. Leu’s research interests include additive manufacturing, cyber-physical manufacturing, robotics and automation, and product lifecycle management. He has published over 400 papers in refereed publications in professional journals and conference proceedings. Also, he has written one e-book and 10 book chapters, and has been granted 4 U.S. patents. Leu has received a few professional awards, including the University of Missouri President’s Leadership Award (2017), ASME Blackall Machine Tool and Gage Award (2014), ISFA Hideo Hanafusa Outstanding Investigator Award (2008), ASME Distinguished Service Award (2004), NJIT Harlan J. Perlis Research Award (1993), NSF Presidential Young Investigator Award (1985), SAE Ralph R. Teetor Education Award (1985), and FPRS Wood Paper Award (1981), and was on the NJIT team to receive the CASA/SME University Lead Award (1994). He was elected to CIRP Fellow in 2008 and to ASME Fellow in 1993, and is a member of Sigma Xi, Tau Beta Pi, and Phi Kappa Phi honor societies.

Richard Hague, University of Nottingham
Presentation Title: "Enabling Next Generation Additive Manufacturing: the 3D Deposition of Functional Materials for the Additive Manufacturing of Smart Devices - a UK perspective"

Though many of the emerging industrial examples of additive manufacturing are highly promising, by their single material nature, they also are limited to being used as “passive” entities that have little functionality beyond being structural. Taking the concept of design freedom beyond the geometrical domain to one where multiple materials are contemporaneously deposited opens-up the potential for the creation of complex, functionalized, “active” printed devices. However, though simple in concept, this discrete deposition of dissimilar materials throughout a 3D volume creates significant technical challenges, particularly in the deposition of useful materials.

This presentation will firstly give an overview of the UK AM landscape and then give a realistic view of the state of the art of “multifunctional” AM from both the UK and beyond. It will then focus on the current activities of the Centre for Additive Manufacturing (CfAM) at the University of Nottingham where a coordinate Programs of activity into next-generation, multifunctional AM is being undertaken. Principally funded by the UK’s national Science funder (EPSRC) and working with key industry, this research is predominantly, but not exclusively, utilizing novel jetting-based technologies for the co-deposition of both structural and functional materials for electronic, pharmaceutical and biological structures and devices over varying length scales.

About the Presenter: Richard Hague is Professor of Innovative Manufacturing and Director of the Centre for Additive Manufacturing (CfAM) at the University of Nottingham. Having worked in the AM field for over 24 years, he is internationally recognized both for scientific endeavor and creating impact though industrial exploitation where he has a background of leading and managing large multi-disciplinary, multi- partner research projects from both EPSRC and industry. Hague’s research interests are focused on AM specific processes, materials and computational methods across for wide spectrum of industrial sectors with current research programs focused on next generation multifunctional additive manufacturing. Richard has received multiple international awards and honors and is a co-founder and Director of Added Scientific Ltd, a spin out from the University of Nottingham focused on implementing Additive Manufacturing technical solutions to industry.

Ma Qian, Royal Melbourne Institute of Technology (RMIT University)
Presentation Title: "Metal Additive Manufacturing in Australasia and China"

As part of the comprehensive TMS2018 Forum on metal additive manufacturing (AM), this contribution provides an overview of the development and trends in metal AM in Australasia and China (partial review). The emphases is placed on (i) metal AM products and innovative developments in metal AM processes and topological design in Australasia; (ii) governments and industry driven initiatives on metal AM in Australasia; and (iii) current status and the Central Government’s active drive for metal AM in China.

About the Presenter: Ma Qian is Professor of Advanced Manufacturing and Materials of School of Engineering at Royal Melbourne Institute of Technology (RMIT University), and Honorary Professor of Materials Engineering at The University of Queensland, Australia. He is currently Deputy Director of RMIT Centre for Additive Manufacturing (AM). Qian’s areas of research include powder metallurgy, solidification processing and materials issues associated with metal AM. He has published 201 peer-reviewed journal papers in these areas and has one patent commercialized. In addition, he has co-authored a 5th edition Elsevier book Light Alloys: Metallurgy of Light Metals (2017, with I. Polmear, D. H. StJohn and J. F. Nie) and co-edited two Elsevier books on Titanium Powder Metallurgy: Science, Technology and Applications (2015) and Titanium in Medical and Dental Applications (2017), both with Professor F. H. Froes. Achieved together with his collaborators and team, his recent fundamental contributions to metal AM include (i) the development of in-situ martensite-decomposition based selective laser melting (SLM) processes of Ti-6Al-4V (Acta Mater 2015:85;74-84) and (ii) the identification of massive phase transformation and its contribution to microstructural formation in selective electron beam melting (SEBM) of Ti-6Al-4V (Acta Mater 2016:104;303-311). He initiated a TMS co-sponsored biannual International Conference on Titanium Powder Metallurgy in 2011, which has been held consecutively in Australia, New Zealand, Germany and China.

Todd Palmer, Pennsylvania State University
Presentation Title: "Additive Manufacturing of Metals: Current Status and Future Outlook"

The Additive Manufacturing (AM) of metallic systems represents both great promise for the larger scale application of AM and challenges in producing structurally sound components with consistent material properties. The characteristic layer-by-layer deposition of the AM process produces complex processing conditions that can lead to unique microstructures and properties. In addition, it provides the opportunity to much more easily integrate different materials into complex geometries. Significant work is being undertaken globally on improving the process understanding as well as characterizing material properties in AM fabricated monolithic and functionally graded metallic components. Much of this future promise for AM processing of metals will depend on the development of new alloy systems and improved understanding and control of the processing conditions. Recent road mapping efforts have identified future directions for research in these areas, and progress on selected tasks will be reviewed.

About the Presenter: Todd A. Palmer is currently a Professor of Engineering Science and Mechanics and Materials Science and Engineering at the Pennsylvania State University. Previously, he was a metallurgist at Lawrence Livermore National Laboratory. His current research focuses on the laser and electron beam joining and additive manufacturing of metallic materials. He is the author of more than 80 articles and reports and is currently chair of the C7 Committee on High Energy Beam Welding and Cutting. Palmer has received numerous awards from several technical societies, including the Adams Memorial Membership Award (2015), McKay-Helm Award (2010 and 2017), A. F. Davis Silver Medal Award (2007 and 2008), Koichi Masubuchi Award (2006), and William Spraragen Memorial Award (2005) from the American Welding Society, and the Geoffrey Belton Award of The Iron and Steel Society (2000). From June 1995 to June 1998, he received an American Welding Society Graduate Research Fellowship. He earned his PhD in Materials Science and Engineering (1999) from Pennsylvania State University under Prof. T. DebRoy and also holds a master of business administration degree from Pennsylvania State University.

Dave Rosen, Georgia Institute of Technology /Singapore University of Design
Presentation Title: "Polymers in Additive Manufacturing: Survey and Opportunities"

Despite the rapid growth of the Additive Manufacturing (AM) field, the range of polymer materials available for AM is far smaller than the breadth of polymers available for conventional manufacturing processes. This is due, in part, to the complexities of the coupled interacting physical and chemical phenomena occurring in AM processes. On the other hand, the unique capabilities of AM offer opportunities for developments of new polymer materials, composites, functionally graded materials, hierarchically structured materials, and others. In this talk, a survey is given of polymer materials and their AM processes. Opportunities for new polymer-based materials are identified and illustrated with recent research results.

About the Presenter: David Rosen is a Professor in the Engineering Product Development pillar at the Singapore University of Technology & Design, as well as a Professor in the School of Mechanical Engineering at the Georgia Institute of Technology (on leave). He is the Research Director of the Digital Manufacturing and Design Centre at SUTD. He received his Ph.D. at the University of Massachusetts in 1992 in mechanical engineering. His research interests lie at the intersection of design, manufacturing, and computing with specific focus on additive manufacturing, computer-aided design, and design methodology. He has industry experience, working as a software engineer at Computervision Corp. and a Visiting Research Scientist at Ford Research Laboratories. He is a Fellow of ASME and has served on the ASME Computers and Information in Engineering Division Executive Committee. He is the recipient of the 2013 Solid Freeform Fabrication Symposium, International Freeform and Additive Manufacturing Excellence (FAME) Award and the co-author of a leading textbook in the AM field.

Suman Das, Georgia Institute of Technology
Topic: Ceramics for Additive Manufacturing

Additive manufacturing of ceramics is an increasingly important area of research and development with applications spanning aerospace and defense, biotechnology, electronics, energy, metal casting, and several other sectors. A number of AM ceramics technologies were developed in the mid-1990s spurred by large US funding. These included, for example, robocasting, ceramic stereolithography, and ceramic slurry extrusion. In most cases, the processing was indirect and required thermal post-processing to eliminate transient binders and develop final properties. More recently, direct processing including laser sintering techniques have been developed. Several common direct and indirect ceramic AM methodologies will be presented in this talk. Emphasis will be placed on a novel technique developed by the presenter, Large Area Maskless Photopolymerization (LAMP). While broadly capable of a range of applications and ceramic systems, this approach is especially well-suited for printing high-precision ceramic cores and shell molds for investment casting of complex metal parts. About the Presenter: Suman Das is the Morris M. Bryan, Jr. Chair in Mechanical Engineering for Advanced Manufacturing Systems, professor of mechanical engineering and of materials science and engineering at Georgia Tech. He is the director of the Direct Digital Manufacturing Laboratory. His research interests cover advanced 3D printing and additive manufacturing in metals, ceramics and polymers through a synergistic combination of computational design methods, materials processing technologies, and materials science. Applications of his research are aimed at the aerospace, biomedical, energy and nanotechnology sectors. He has published over 180 technical articles and holds 7 patents.