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  • 1.  Metal Additive Manufacturing using Powder Sheets (MAPS)

    Posted 14 days ago

    Dear community,

    within my research group we are developing an innovative coating technology, that is based upon a new material known as the "powder sheet". The powder sheet is made out of mostly metal powder, and a small polymer %. The sheets feels on the touch like paper, they are flexible and not rigid. When placing a sheet section over a substrate area, and after laser irradiation (such as in laser cladding), the polymer degrades immediately and the metal powder in the sheets fuses to form a coating that is dense right the way and is attached to the substrate area (no need to post-process). Multiple sheets can be added to increase the coating thickness.

    Some key advantages:

    -Elimination of powder feeders and loose powder.

    -Elimination of the need to create very flowable powder. Conventional powders and irregular powders work just as well and using a variety of PSDs.

    -Easiness for multi-material possibilities, and multi-material powder blends.

    -The bond between the coating and the surface material is metallurgical (hence there must be materials compatibility).

    -Zero scrap. Unused sheets (or sheet parts) during processing can be recycled to make new sheets.

    You can find some recent papers on this process (they are open access):

    https://doi.org/10.1016/j.cirp.2022.03.012

    https://doi.org/10.1080/17452759.2024.2361856

    The process is still at its early stages, but we are looking specifically for industrial interest to scope for possible applications in the coatings market. The interest is welcomed in many forms, from coating development to process development to machine development.

    If you would like to know more and are interested in the technology, please reach out to me via email (lupoi@tcd.ie) or LinkedIn (www.linkedin.com/in/rocco-lupoi)

    Rocco Lupoi, MEng, PhD, FTCD, FIMMM

    Associate Professor (additive and advanced manufacturing)

    TCD Co-Director for the SFI-EPSRC Centre for Doctoral Training in Advanced Characterization of Materials

    E-mail:   lupoir@tcd.ie

    Office:   +353 (0) 18961729

    • Personal Profile
    • PI of STAM
    • Funded Investigator in AMBER, the SFI Research Centre for Advanced Materials and BioEngineering Research
    • Funded Investigator in I-Formthe SFI Research Centre for Advanced Manufacturing

    Trinity College Dublin, The University of Dublin

    Department of Mechanical, Manufacturing & Biomedical Engineering
    Parsons Building
    Dublin 2
    Ireland



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    Rocco Lupoi
    Trinity College Dublin
    Castleknock
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    TSS Open Mic Series


  • 2.  RE: Metal Additive Manufacturing using Powder Sheets (MAPS)

    Posted 13 days ago
    Kennametal in New Albany. Indiana has a similar process called Conforma Clad, used for applying Ni base brazing alloys for hardfacing.

    Best regards,

    Bob Miller
    6533 Woodmere Circle
    Indianapolis, IN 46260 USA
    +1 317-698-5479 Mobile
    +1 317-259-7632 Home



    TSS Open Mic Series


  • 3.  RE: Metal Additive Manufacturing using Powder Sheets (MAPS)

    Posted 13 days ago
    Correction:
    The main Conforma Clad materials lately are combinations of Tungsten Carbide with Cobalt base alloys, applied as a powder sheet containing binder.  The basic process goes back decades.


    Best regards,

    Bob Miller
    6533 Woodmere Circle
    Indianapolis, IN 46260 USA
    +1 317-698-5479 Mobile
    +1 317-259-7632 Home



    TSS Open Mic Series


  • 4.  RE: Metal Additive Manufacturing using Powder Sheets (MAPS)

    Posted 13 days ago

    Hello Robert, many thanks for reading the post and for your comments. Yes, Conforma Clad is a valuable example and you will find others (commercial and not). The MAPS sheets are however quite different due to advantageous details (which I am not able to share in full) in their formulation and in the way/time it takes to be processed. 



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    Rocco Lupoi
    Trinity College Dublin
    Castleknock
    ------------------------------

    TSS Open Mic Series