Metal-based additive processes, such as laser-based direct metal deposition, fused deposition modeling, three-dimensional printing, selective laser sintering, and selective laser melting, are promising emerging manufacturing technologies for producing complex and highly-customized parts. These processes have been in development over the past 15+ years and their capabilities have grown significantly. However, several barriers have prevented metal-based additive processes from reaching their potential. These barriers include limitations in uncertainties about the material properties of the raw unprocessed metal powder and the final parts, a lack of understanding of the processes themselves, poor surface quality and part accuracy, and limitations in fabrication speed.

We are interested in projects that focus on the development and application of measurement techniques, science-based models, and standards to better understand and improve metal-based additive processes. Our facilities include a commercial direct metal laser sintering machine, and measurement tools for manufacturing process characterization such as high-speed micro-videography in both infrared and visible spectra and FEM-based simulation and analysis software. Through collaboration with other NIST laboratories, we also have access to a full spectrum of techniques for material and geometry characterization at the micro and macro scales.

 

Keywords:

Additive manufacturing; Direct metal laser sintering; Materials characterization; Metal powder; Powder bed fusion; Process metrology;

Citizenship:  Open to U.S. citizens

Level:  Open to Postdoctoral applicants