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.