![]() The first project demonstrator, an AM machine capable of printing in resins using holographic projection is discussed in Section 6.2. Algorithms developed for the project are introduced in Chapter 4.3. The first deliverable, a reusable software package capable of generating holograms, is presented in Chapter 4. Chapters 2 and 3 then provide more detail on CGH and AM modelling respectively. The fields of additive manufacture and computer-generated holography are introduced in Chapter 1. It will also significantly reduce thermal gradients and melt-pool instability. ![]() Projecting power to the whole layer at once will mean that the thermal properties of the powders before and after writing can be factored into the processed hologram and part design. This thesis sets out initial research into creating a radically new AM process that uses computer-generated holography (CGH) to produce complex light patterns in a single pulse. These factors have led to frequent inability to ensure part quality without physical prototyping and destructive testing. The scale difference between the part size and the spot size means that predictive modelling is beyond the scope of even today’s best computing clusters. Mechanical limitations in the galvoscanner mean that over or under-heating is common and can lead to voids, boiling and spatter. The rapidly moving heat source spot results in high thermal cycling and is a major influence on residual stress and distortion. Traditional AM systems have limited ability to manage or compensate for heat generated. Powder is spread in layers 10s of microns thick and selectively melted by scanning a small laser spot heat source over the bed. AM in metals is dominated by Laser Powder Based Fusion (L-PBF). Widely used in applications from hip implants to jet engines, AM remains the domain of experts due to the material and thermal challenges encountered. AM promises to help reduce emissions and waste during manufacture while improving sustainability. With a market of approximately $10B, additive manufacture (AM) is an exciting next-generation technology with the promise of significant environmental and societal impact.
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