Cost modelling of metal laser powder-bed systems

Abstract

Additive manufacturing (AM) has been dubbed as the ‘third industrial revolution’ of this age, due to its huge potential in altering the dynamics of the manufacturing market. In particular, this report has chosen to focus on metal AM, because it has shownimmense capabilities to manufacture complex components to high standards for demanding applications in the aerospace and medical sectors. More importantly, AM has brought about distinct advantages, such as supply chain process simplification and its versatile ability to manufacture parts without restriction from conventional design rules. However, widespread adoption of AM has been hindered due to huge costs and a lack of robust cost models to gain visibility into the economics of AM when compared with traditional manufacturing methods. Building on my predecessors’ work, this report aims to address this knowledge gap, through creation of a macro-level broad business framework integrated with microlevel cost models through understanding the needs of the manufacturing industry. The traditional manufacturing method which will be focused on will be machining, since they are most significantly challenging AM’s viability for mass manufacturing. Case studies of various parts will be used to illustrate and validate the process flow and cost models, providing reasonably accurate cost estimates with cost comparisons between AM and machining. The end goal of this project is to equip clients of the Advanced Remanufacturing and Technology Centre (ARTC) with this framework, for them to determine which manufacturing method is the most cost- and time-efficient to manufacture a part.