post-processing

Post-Processing for Directed Energy Deposition Metal Additive Manufacturing

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Published on Aug 16, 2019 SKU SMP-AM-PPDED-0819 Category Tags ,
Table of Contents

Chapter One: Introduction
Chapter Two: Challenges in Post-Processing DED Parts
2.1 Part Removal
2.2 Thermal Post-Processing
2.2.1 Heat Treatment
2.2.2 Solution Treatment Aging (STA) / Age Hardening
2.2.3 Hot Isostatic Pressing (HIP)
2.3 Machining
2.4 Surface Finishing
2.4.1 Contact Surface Finishing
2.4.1.1 Sand Blasting and Shot Peening
2.4.1.2 Centrifugal Disc Finishing (CDF)
2.4.1.3 Centrifugal Barrel Finishing (CBF)
2.4.1.4 Reverse Drag Finishing (RDF)
2.4.2 Laser Surface Finishing
2.4.2.1 Benefits of Laser Surface Finishing
2.4.2.2 Limitations of Laser Surface Finishing
2.4.2.3 Laser Surface Finishing Methods
2.4.3 Electron Beam Polishing
2.4.4 Electropolishing and Electrochemical Machining (ECM)
2.4.5 Chemical Polishing
2.4.6 Chemically Accelerated Vibratory Finishing
2.4.7 Abrasive Flow Machining
Chapter Three: Cost Considerations for Post-Processing Metal AM Parts
3.1 Relative Cost Drivers by Printer Technology
3.2 Relative Cost Drivers by Process
3.2.1 Part Separation and Support Removal
3.2.2 Heat Treatment, HIP and Precipitation Hardening
3.2.3 Surface Finishing
3.3 Hidden Costs
3.3.1 Underestimation of Surface Finish Time
3.3.2 Inadequate Tools for Interior Finishing
3.3.3 Process Knowledge
3.3.4 Skills Gap
3.4 Comprehensive Costs
3.5 A Comparison Across Common Alloys
Chapter Four: Post-Processing OEMs and Service Providers
4.1 Post-Processing Equipment OEMs
4.1.1 Thermal Treatment / HIP
4.1.2 Surface Finishing
4.1.2.1 Laser Surface Finishing
4.1.2.2 Electron Beam Polishing
4.1.2.3 Electropolishing
4.1.2.4 Electro-chemical Finishing
4.1.2.5 Combined Systems
4.1.3 Hybrid Machining
4.2 Post-Processing Service Providers
4.3 Summary
Chapter Five: Design Considerations to Minimize and Optimize Post-Processing
5.1 Internal Passages
5.2 Thermal Processing
5.3 Surface Finishing
5.4 Machining
Chapter Six: Future Trends
6.1 End-to-end Solutions and Automation
6.2 Data Optimization and Industrial IoT
6.3 Software Solutions
6.4 Standards and Regulations
About SmarTech Analysis
About the Analyst
Acronyms and Abbreviations Used In this Report

As additive manufacturing of metal parts continues to transform from prototyping to production, we’ve seen materials expand, systems improve, and automation advance. But, until recently, we haven’t seen an increased focus on post-processing, especially as it pertains to directed energy deposition (DED).

With that said, in this report, we look at the common post-processing steps for DED parts, what they can achieve, and the challenges observed. We will discuss the relative cost considerations to keep in mind as well as costs that often go unaccounted for in the workflow. We will also discuss many of the OEMs and service providers that are active in this space. And, often forgotten, we will discuss some of the critical considerations in the design stage that can greatly influence the directed energy deposition post-processing stage in the overall workflow. We finish with a discussion on the future trends, to include end-to-end solutions and automation, data optimization, software solutions, and the current state of standard and regulations as they pertain to post-processing in general.