Functional integration approaches via laser powder bed processing

Additive manufacturing design rules are different from those of conventional fabrication techniques. These allow geometries that would not be possible to achieve otherwise. One example of application is the integration of functional parts as part of the manufacturing process. Conceivable applications range from mechanical functions like integration of moving parts or thermodynamic functions, for example, cooling channels or incorporation of electric circuits for electrical functionalization [J. Glasschroeder, E. Prager, and M. F. Zaeh, Rapid Prototyping J. 21, 207–215 (2015)]. Nevertheless, the potential of functional integration using powder-bed processes is far from being exhausted. The present approach addresses the generation of inner cavities and internal structures of titanium-based parts or components by the use of selective laser melting. This paper focusses on the investigation of voids and cavities regarding their capabilities to add new functions to the material. To this end, comprehensive characterization is performed using destructive as well as nondestructive testing methods. These include 3D scanning, computed tomography, and surface roughness measurements as well as microscopic analysis. Voids and cavities were filled with different thermoplastic materials, followed by the qualitative assessment of the mold filling and resulting material properties. Finally, applications are derived and evaluated with respect to the field of lightweight design or damping structures.