Material incorporation in powder sheet additive manufacturing toward lightweight designs for future mobility

Additive manufacturing of AlSi10Mg has obtained increased attention due to its lightweight feature. However, handling of loose powder, efficient usage of feedstock, and powder recycling still remain major open challenges. Herein, a novel additive manufacturing method based on metal additive manufacturing using powder sheet (MAPS) is proposed, which leverages composite flexible films made of the feedstock of metal powder and a polymeric binder, aiming to extend the range of applicability of AlSi10Mg-based additive manufacturing technologies, for example, vehicle components. In situ high-speed imaging is used to explore the underlying manufacturing mechanisms of the proposed MAPS concept and investigate the laser–powder sheet interaction. In addition, a representative computational thermo-mechanical model was used to evaluate the substrate deformation due to the printing process, a critical aspect that must be minimized in order to transfer this technology to larger scale applications.