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Exceeding the Limits in Laser Materials Processing by Bridging Additive and Subtractive Manufacturing with Continuous Wave and Ultrashort Pulsed Lasers - Manufacturing of Parts with Undercuts

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Laser 3D Manufacturing XI, Volume 12876 von Proc. SPIE, SPIE, (März 2024)
DOI: 10.1117/12.3003688

Zusammenfassung

Laser-based powder bed fusion of metals faces limitations in accuracy, surface quality, and minimal structure size resulting from the inherent melting process. To address these challenges, a novel approach integrating additive and subtractive laser processes at the layer level has been developed. This quasi-simultaneous manufacturing process enables the fabrication of small structures with high aspect ratios, including narrow slits below 50 μm in width. The implications of this advancement are promising, particularly in the fields of electric drives and fuel cells, where accuracy and freedom of design are crucial. In this work, the latest results of the production of narrow, inclined slits in components made of pure iron will be shown. Characteristics like groove-to-groove distance and groove width were analyzed, achieving successful production of continuous slits with varying inclination angles of up to 30° within the manufactured components.

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