PREDICTIVE THEORETICAL AND
COMPUTATIONAL APPROACHES FOR
ADDITIVE MANUFACTURING
Proceedings of a Workshop
Michelle Schwalbe, Rapporteur
U.S. National Committee on Theoretical and Applied Mechanics
Board on International Scientific Organizations
Policy and Global Affairs
THE NATIONAL ACADEMIES PRESS
Washington, DC
www.nap.edu
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This workshop was supported by Grant No. CMMI-1545752 from the National Science Foundation. The Proceedings of a Workshop was supported by Grant No. 60NANB15D281 from the National Institute of Standards and Technology and Grant No. DE-AC04-94AL85000 from Sandia National Laboratories. Any opinions expressed in this publication are those of the rapporteur and do not necessarily reflect the views of any organization or agency that provided support for the project.
International Standard Book Number 13: 978-0-309-44975-5
International Standard Book Number 10: 0-309-44975-8
Digital Object Identifier: 10.17226/23646
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Suggested citation: National Academies of Sciences, Engineering, and Medicine. 2016. Predictive Theoretical and Computational Approaches for Additive Manufacturing: Proceedings of a Workshop. Washington, DC: the National Academies Press. doi: 10.17226/23646.
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PLANNING COMMITTEE ON PREDICTIVE THEORETICAL AND COMPUTATIONAL APPROACHES FOR ADDITIVE MANUFACTURING
WING KAM LIU (Chair), Northwestern University
ELIZABETH CANTWELL, Arizona State University
ANTHONY DeCARMINE, Oxford Performance Materials
SLADE GARDNER, Lockheed Martin Space Systems Company
THOMAS KURFESS, Georgia Institute of Technology
EDWARD MORRIS, National Center for Defense Manufacturing and Machining
Staff
ANA M. FERRERAS, Senior Program Officer
PAMELA GAMBLE, Administrative Associate
U.S. NATIONAL COMMITTEE FOR THEORETICAL AND APPLIED MECHANICS
Officers
WING KAM LIU (Chair), Northwestern University
GARETH H. MCKINLEY (Vice Chair), Massachusetts Institute of Technology
LINDA P. FRANZONI (Secretary), Duke University
STELIOS KYRIAKIDES (Past Chair), NAE,1 University of Texas at Austin
Members-at-Large
JOHN DABIRI, Stanford University
ANN KARAGOZIAN, University of California, Los Angeles
CHAD LANDIS, The University of Texas at Austin
THOMAS J. PENCE, Michigan State University
Society Representatives
ACOUSTICAL SOCIETY OF AMERICA (ASA), Linda Franzoni, Duke University
AMERICAN ACADEMY OF MECHANICS (AAM), Chad Landis, The University of Texas at Austin
AMERICAN INSTITUTE OF CHEMICAL ENGINEERS (AIChE), Paul Steen, Cornell University
AMERICAN MATHEMATICAL SOCIETY (AMS), Eitan Tadmor, University of Maryland, College Park
AMERICAN PHYSICAL SOCIETY (APS), Beverley McKeon, California Institute of Technology
AMERICAN SOCIETY OF CIVIL ENGINEERS (ASCE), Roger Ghanem, University of Southern California
AMERICAN SOCIETY OF MECHANICAL ENGINEERS (ASME), Nadine Aubry, NAE, Northeastern University
ASTM INTERNATIONAL (formerly American Society for Testing and Materials), Steven Daniewicz, Mississippi State University
___________________
1 The National Academy of Engineering.
SOCIETY FOR EXPERIMENTAL MECHANICS (SEM), Wendy Crone, University of Wisconsin, Madison
SOCIETY FOR INDUSTRIAL AND APPLIED MATHEMATICS (SIAM), Qiang Du, Columbia University
SOCIETY OF ENGINEERING SCIENCE (SES), Horacio D. Espinosa, Northwestern University
SOCIETY OF ENGINEERING SCIENCE (SES), Kyung-Suk Kim, Brown University
SOCIETY OF RHEOLOGY (SOR), Eric S.G. Shaqfeh, NAE, Stanford University
UNITED STATES ASSOCIATION FOR COMPUTATIONAL MECHANICS (USACM), Tarek Zohdi, University of California, Berkeley
Ex Officio Members
JIANMIN QU, Tufts University
Staff
ANA M. FERRERAS, Senior Program Officer
PAMELA GAMBLE, Administrative Associate
BOARD ON INTERNATIONAL SCIENTIFIC ORGANIZATIONS
Members
MICHAEL CLEGG (Chair), NAS,1 University of California, Irvine
PATRICK SCOTT (Vice Chair), Los Alamos National Laboratory Foundation
ALLAN C. ASHWORTH, North Dakota State University
ASMERET ASEFAW BERHE, University of California, Merced
MELODY BROWN BURKINS, Dartmouth College
RONALD GRAHAM, NAS, University of California, San Diego
MARVIN HACKERT, University of Texas at Austin
KENNETH KELLERMANN, NAS, National Radio Astronomy Observatory
WING KAM LIU, Northwestern University
C. BRADLEY MOORE, NAS, University of California, Berkeley
KENNEDY REED, Lawrence Livermore National Laboratory
DONALD SAARI, NAS, University of California, Irvine
JEFFREY ZACKS, Washington University in St. Louis
Ex Officio Members
JOHN HILDEBRAND, NAS, University of Arizona, Tucson
MICHAEL CLEGG (Chair), NAS,2 University of California, Irvine
Staff
KATHIE BAILEY, Director
ESTER SZTEIN, Assistant Director and Senior Program Officer
ANA M. FERRERAS, Senior Program Officer
LOIS PETERSON KENT, Senior Program Officer
PAMELA GAMBLE, Administrative Associate
CHELSEA BOCK, Program Coordinator
___________________
1 The National Academy of Sciences.
2 The National Academy of Sciences.
Acknowledgments
We would like to thank the following staff members for their contributions to this report: Ana Ferreras, Senior Program Officer; Michelle K. Schwalbe, Senior Program Officer; Aqila A. Coulhurst, Associate Program Officer; and Linda Casola, Staff Editor.
REVIEWERS
This report has been reviewed in draft form by individuals chosen for their diverse perspectives and technical expertise, in accordance with procedures approved by the National Academies of Sciences, Engineering, and Medicine’s Report Review Committee. The purpose of this independent review is to provide candid and critical comments that will assist the institution in making its published report as sound as possible and to ensure that the report meets institutional standards for quality and objectivity. The review comments and draft manuscript remain confidential to protect the integrity of the process.
We wish to thank the following individuals for their review of this report: Michael Gorelik, Federal Aviation Administration; Lonnie Love, Oak Ridge National Laboratory; Amit Misra, University of Michigan; Edwin Schwalbach, Air Force Research Laboratory; and Tarek Zohdi, University of California, Berkeley.
Although the reviewers listed above have provided many constructive comments and suggestions, they were not asked to endorse the content of
the report, nor did they see the final draft before its release. The review of this report was overseen by Robert Schafrik (Retired), General Electric Aviation. Appointed by the National Academies, he was responsible for making certain that an independent examination of this report was carried out in accordance with institutional procedures and that all review comments were carefully considered. Responsibility for the final content of this report rests entirely with the rapporteur and the institution.
Wing Kam Liu
Chair, Planning Committee
Contents
2 THEORETICAL UNDERSTANDING OF MATERIALS SCIENCE AND MECHANICS
Challenges in Additive Manufacturing of Soft Materials: Polymer-based Fused Deposition Modeling
Modeling and Simulations of Additive Manufacturing
Theoretical Understanding of Materials Science and Mechanics
Part-Level Finite Element Simulation of Selective Laser Melting
Main Physical Phenomena in Metal Powder-Bed Fusion
3 COMPUTATIONAL AND ANALYTICAL METHODS IN ADDITIVE MANUFACTURING
Computational and Analytical Needs in Additive Manufacturing
Computational and Analytical Methods in Additive Manufacturing: Linking Process to Microstructure
Additive Manufacturing Challenges for Computational Solid Mechanics
4 MONITORING AND ADVANCED DIAGNOSTICS TO ENABLE ADDITIVE MANUFACTURING FUNDAMENTAL UNDERSTANDING
Process Modeling and Diagnostic Considerations
Barriers to Widespread Additive Manufacturing
Directed Energy Deposition and Electrospinning
In-Process Sensing of Laser Powder-Bed Fusion Additive Manufacturing
5 ADDITIVE MANUFACTURING SCALABILITY, IMPLEMENTATION, READINESS, AND TRANSITION
Additive Manufacturing: Capabilities, Challenges, and the Future
A Different Perspective on Scalability and Public-Private Partnership
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