Enhancing the performance of laser powder bed fusion through hybridization with bending

This paper is focused on the hybridization of metal additive manufacturing with bending to shape thin-walled deposited materials into fully three-dimensional custom parts with specific angles. The presentation covers material deposition by laser powder bed fusion, material and formability characterization using tension and three-point bending tests, and proof-of-concept validation through bending a flat, cross-shaped, deposited plate into a slender three-dimensional double U-shaped part. The use of digital image correlation and finite element analysis supports the presentation as well as the design and creation of the part. Results underscore the significance of hybridizing metal additive manufacturing with bending due to the gains obtained in material usage and fabrication time of 87.9 % and 85.7 %, respectively. The overall methodology integrating material deposition, formability analysis, and combined experimental and finite element simulation of bending proves effective for designing hybrid metal additive-manufactured parts, providing a comprehensive framework for future research and development in this area.