Bound Metal Deposition (BMD) is an alternative to the most common additive manufacturing (AM) technology for metal parts, Powder Bed Fusion (PBF), since the equipment used is more affordable and there are no risks due to exposure to loose powder and lasers or beams. However, the mechanical properties of parts manufactured by BMD are generally lower than those of PBF, making it necessary to study the process parameters to improve their performance. The aim of this work was to analyse the effect of different process parameters on the mechanical properties of 316L parts manufactured by BMD based on a set of specially designed experiments. The methodology followed in this research was thus based on the manufacturing of a series of samples with variations of the build orientation, infill pattern and chamber temperature followed by subsequent characterization and analysis. The microstructural analysis showed that voids were formed as a consequence of the air gaps generated between rasters during printing. It was observed that the characteristics of these macropores had a significant effect on the mechanical properties. The location, distribution and shape of these macropores depended on the alignment of rasters in each of the conditions, which varied with build orientation and infill pattern. Regarding the build orientation, horizontal parts exhibited lower porosity and considerably higher ultimate tensile strengths (UTS), approximately 160 MPa higher, than vertical samples. With respect to the infill pattern, horizontal parts with a concentric infill pattern showed triangular voids and a total porosity higher than 5%. However, samples with line infill patterns presented elongated macropores and a total porosity lower than 5%, properties that resulted in an improvement in UTS of 20 MPa, approximately. Overall, the results presented here offer a better comprehension of the effect of the BMD process parameters on mechanical properties and serve as a guideline for future work.

The performance of a precisely controlled drilling technique is critical in the fabrication process of microstructured polymer optical fibres. For the creation of a holey preform, adequate drilling bits with large length-to-diameter ratios provide the ability of machining preforms with complex structures and large lengths in a relatively short time. In this work, we analysed different drilling bits and techniques that can be employed for the creation of such preforms, and key parameters characterising the quality of the drilled holes, such as surface rugosity, diameter deviation, coaxiality and cylindricity were measured. For this purpose, based on theoretical simulations, four rings of air holes arranged in a hexagonal pattern were drilled in the preforms with different drill bits, and the experimental results for the above mentioned parameters have been presented. Additionally, optical power distribution of the fabricated microstructured polymer optical fibres was theoretically calculated and experimentally measured.

Multi Jet Fusion (MJF), an innovative additive manufacturing (AM) technique in the field of Powder Bed Fusion (PBF) developed by Hewlett-Packard (HP) Inc. (Palo Alto, CA, USA), has been designed to produce polymer parts using thermoplastic-based powders, primarily focusing on polyamide 12 (PA12). Employing a layer-by-layer approach, MJF enables the rapid production of intricate components, reportedly up to 10 times faster than other AM processes. While the mechanical properties of MJF-printed PA12 and the impact of build orientation on those properties have already been explored in various studies, less attention has been given to the mechanical performance of MJF-printed PA12 components under complex loads and accurate predictive models. This contribution aims to assess the applicability of a constitutive model based on a transversely isotropic behaviour under linear elastic deformation for predicting the mechanical response of MJF-printed PA12 parts through numerical simulations. Both uniaxial tensile and shear tests were carried out on printed samples to determine the elastic properties of MJF-printed PA12, with additional testing on printed complex handle-shaped parts. Finally, a numerical model was developed to simulate the mechanical tests of the handles. Results from tests on printed samples showed that MJF-printed PA12, to some extent, behaves as a transversely isotropic material. Furthermore, using a constitutive model that assumes a transversely isotropic behaviour under linear elastic deformation for predicting the mechanical response of MJF-printed PA12 parts in numerical simulations could be a reasonable approach, provided that the material stress levels remain within the linear range. However, the particularities of the stress-strain curve of MJF-printed PA12 complicate determining the elasticity-to-plasticity transition point.

The high cooling rates reached during metal additive manufacturing (MAM) generate microstructures very different from those obtained by other conventional manufacturing methods. Therefore, research about the modeling of this type of microstructure is of great interest to the MAM community. In this work, the prediction of the lamellar spacing of an AlSi10Mg sample manufactured by laser powder bed fusion (LPBF), is presented. A multiscale approach is used, combining a CALPHAD (Computer Coupling of Phase Diagrams and Thermochemistry) model to predict the material properties, with a macroscale model of the sample manufacturing and with a microscale model to predict the microstructure. The manufacturing and metallographic characterization of the sample is also included. The results prove that the multiscale strategy followed is a valid approximation to simulate this type of manufacturing process. In addition, it is shown that the use of a generic simulation software focused on metal casting processes can be useful in predicting the lamellar spacing of the microstructure manufactured by LPBF. Finally, the relationship between the cooling rate and the resulting lamellar spacing has been established for this AlSi10Mg under the specific manufacturing conditions considered.