Multi-material processing in additive manufacturing

One of the most important advantages of additive layer manufacturing (ALM) is the ability to produce parts with high geometric complexity in a very economical manner. However, only little effort has been taken in order to enhance aspects of material flexibility of ALM. A modified manufacturing process was developed and different stages concerning the dimensions of multimaterial complexity are defined. The technological base being selective laser melting, two varying metallic materials were fused within each layer. Therefore, a new recoating mechanism for non-cohesive powders has been developed. To increase lifetime of tools with abrasive wear environment, hot work steel and tungsten carbide/cobalt have been combined. A tooling insert has been chosen as an example of application.