Restoration and Reinforcement of Desktop Laser Powder Bed Fusion Additive Manufacturing System

Abstract

This thesis details the restoration and reinforcement of a desktop Laser Powder Bed Fusion (LPBF) additive manufacturing system originally designed and built three years prior. The primary focus was addressing a malfunctioning powder loading system, which hindered the printer's functionality. Through a systematic investigation, the cause of the malfunction was identified as a combination of a broken Archimedes' screw and misalignment due to motor wobble. The thesis documents the process of disassembling the printer, evaluating the wear and tear on individual components, and implementing solutions. This involved reprinting parts exhibiting wear and redesigning components prone to failure, specifically the Archimedes' screw and leftover powder reservoir. The redesign focused on increasing the thickness of critical sections to improve strength and adjusting dimensions to ensure proper fit and function within the system. Finite Element Analysis (FEA) was employed to assess the impact of design modifications on the strength of the redesigned components. The results demonstrated a significant reduction in stress levels, indicating improved durability and resistance to failure. Following the integration of the redesigned and reprinted parts, the powder loading system's functionality was successfully restored, and the overall LPBF system's robustness was enhanced. The thesis concludes by presenting key findings and recommendations for future work, emphasizing opportunities to further increase the printer's reliability and explore potential upgrades for enhanced automation and control.