Research Overview

Goal: The overall goal of the NSERC HI-AM Network is to provide realistic, transferable solutions for the foremost challenges preventing industry from converting their conventional manufacturing methods into metal AM processes. Attaining this goal through HI-AM’s research activities will:

HI-AM researchers and their partners are working to improve the quality of additively manufactured parts, process reliability and performance, cost efficiency, and scalability for the following standard metal AM processes:

Research Themes

The research program proposed by HI-AM is working toward these goals within 4 themes, through 14 projects and 39 sub-projects with objectives directly relevant to the research needs of our partner organizations and the research scopes proposed by NSERC in its strategic target areas. These integrative, multidisciplinary, and transdisciplinary research themes include:

HI-AM uses an adaptive management approach, wherein knowledge from each theme will be incorporated within all other themes, in order to achieve the Network goals.

The goal of this theme is to create, test and standardize feedstock metal and metal alloys to broaden the scope of metal parts that can be easily and cost effectively adapted to metal AM processes.

Project 1.1: Development of Next Generation Alloys

Project 1.2: AM processing of multi-material systems

Project 1.3: Cost reduction strategies

The goal of this theme is to develop novel, robust, and efficient numerical models that will become the new tools for simulating different aspects of the Laser- and electron-beam-based PBF and DED processes, along with melt-feedstock interactions and its effects on the finished parts.

Project 2.1: Multi-scale modeling of AM

Project 2.2: Accelerated real-time simulation platforms

Project 2.3: Pre-processing for optimization of AM process parameters

The goal of this theme is to develop novel in- and off-line quality assurance protocols to establish the relationship between in-process feedback data and post-process part characterization. Machine learning algorithms, along with sophisticated monitoring and metrology devices, will effectively monitor defects and disturbances in real-time allowing for adjustments in process parameters through advanced controllers. The end result will push AM technology toward “Certify-as-you-build” platforms.

Project 3.1: Innovative in-situ and ex-situ monitoring strategies for AM-made product quality analysis

Project 3.2: Real-time control and machine learning algorithms for laser powder-bed and powder-fed AM processes

Project 3.3: Intelligent closed-loop control of compaction density for LPB-AM processes

Project 3.4: Process-based adaptive path planning protocols for LPF-AM

The goal of this theme is to use the fundamental knowledge generated in Themes 1 to 3 to accelerate the development of innovative metal AM process parameters and finished-part performance roadmaps that can be certified to ensure the quality and repeatability of AM built parts.

Project 4.1: Innovative AM processes with integrated magnetic systems

Project 4.2: Development of innovative architectural/cellular/lightweight/smart products

Project 4.3: Development of innovative FGM products

Project 4.4: Advanced LPF-AM and PTA-AM for repair and remanufacturing

Research Overview

Goal: The overall goal of the NSERC HI-AM Network is to provide realistic, transferable solutions for the foremost challenges preventing industry from converting their conventional manufacturing methods into metal AM processes. Attaining this goal through HI-AM’s research activities will:

Secure Canadian leadership in the AM sector.

Develop, optimize, and implement new feedstock materials, AM process models and simulations, monitoring sensors and closed-loop control systems, and novel AM processes/products.

Forge lasting relationships between academic institutions, public and private industrial organizations, local and federal governments, and international collaborators.

HI-AM researchers and their partners are working to improve the quality of additively manufactured parts, process reliability and performance, cost efficiency, and scalability for the following standard metal AM processes:

Directed Energy Deposition (DED)

Powder-Bed Fusion (PBF)

Binder Jetting (BJ)

Research Themes

HI-AM uses an adaptive management approach, wherein knowledge from each theme will be incorporated within all other themes, in order to achieve the Network goals.