Framework for developing large-scale metal additive manufacturing (MAM) systems and procedures

Additive manufacturing (AM) is regarded as one of the most disruptive technologies of this era. However, the technology is still evolving, even as new applications continue to emerge, thus presenting an opportunity to manage disruptive changes more efficaciously, whilst strategically shaping critical innovation efforts. Accordingly, this study focusses on supplementary manufacturing requirements management (SMRM). Presently, maintenance challenges, such as the reworking of serviceable infrastructures and other similarly demanding industrial endeavours, contribute to higher costs, inefficiencies, and waste, with technical and other limitations, including disparate supply circumstances and demand patterns, further compounding issues. Underpinned by SMRM applications, the grounded theory (GT) method was applied, to construct a framework for developing large-scale metal AM (MAM) systems and procedures. Case data was derived from the development and commissioning of a unique system and its embodied concepts, which were predominantly enabled by commercial off-the-shelf (COTS) solutions, and subsequent testing and validation of the resulting open architecture (OA) bulk AM (BAM) platform. Empirical and numerical investigations were facilitated by an industrial titanium (Ti-6Al-4V) aerospace component, which demonstrated the suitability and effectiveness of the BAM platform for specific SMRM operations. While the physical and mechanical properties of derived BAM materials were characteristic, and within range of referenced ASTM standards, disparities between the predicted and quantified effects of reprocessing operations on the component necessitate further investigation. The main output of this study is a GT framework, which identifies six strategic developmental themes for more adoptable, compliant, functional, operable, systemical, and adaptable MAM solutions. Important priorities for improving interrelated system functions, procedures, and performance were also defined, alongside an original technical perspectives management concept, for navigating complex requirements in an evolving technology landscape, via the documentation, clarification, validation, and prioritisation of key elements that significantly impact planned innovations.