Public defence in Additive Manufacturing, MSc Rizwan Ullah

Title of the thesis: 3D-finishing of Metal Components Manufactured by the Powder Bed Fusion Process 

Thesis defender: Rizwan Ullah
Opponent: Prof. Antti Salminen, University of Turku, Finland
Custos: Prof. Esko Niemi,Aalto University School of Engineering

Making 3D-printed metal parts geometrically accurate within tight tolerances for industrial use

This study focuses on improving the accuracy and reliability of 3D-printed metal parts. It aims to understand why these parts often become distorted and how to correct them using machining allowances and computer simulations. The work is relevant to industry and other research because it offers practical design guidelines for metal additive manufacturing. Results show that rough surfaces, distorted threads, and setup errors affect quality. The key finding is that machining allowances of about 0.3 mm for linear features and 0.7 mm for curved areas are required. A new FEM simulation model is also introduced, capable of predicting shape changes with less than 30% error. These insights apply to industrial cases like production tooling, where maintaining tight tolerances is critical. Overall, the study concludes that extra machining and predictive modeling are essential for achieving precise and reliable 3D-printed metal components.

Keywords: Laser-based powder bed fusion, 3D-finishing, finite element modeling, geometric deviations,
anisotropy, thread strength  

Thesis available for public display 7 days prior to the defence at Aaltodoc. 

Contact information: 
Rizwan Ullah
LinkedIn profile: https://www.linkedin.com/in/rizwan-ullah-94160066/ 

Research profile: https://research.aalto.fi/fi/persons/rizwan-ullah 

E-mail: rizwanullah1992@gmail.com