Reducing operation qualification time and cost in additive manufacturing

(Press-News.org) America Makes, the National Additive Manufacturing Innovation Institute, is supporting research to revolutionize the additive manufacturing (AM) industry by significantly reducing operational qualification time and cost.

The $2 million project, titled ACCELERATE, is led by Dr. Mohsen Taheri-Andani, an assistant professor in the J. Mike Walker ’66 Department of Mechanical Engineering at Texas A&M University. To secure the funding, Dr. Taheri-Andani partnered with Dr. Yash Parikh, a process engineering consultant at EOS who graduated with a doctorate in mechanical engineering from Texas A&M in 2021.

A central aspect of this project is validating operational qualification through detailed tasks and documentation, which is vital for confirming the AM process to consistently meet material specification requirements. Additionally, the project will tackle various aspects of AM operations — from facility controls and operator training to software configuration and process monitoring. Special emphasis will be placed on feedstock control, machine calibration, and post-processing operations, ensuring thorough quality assurance. 

Dr. Taheri-Andani will lead a research team supporting the project by establishing repeatable and reproducible AM operations, emphasizing installation qualification, operational qualification, and product qualification. 

"Leading this groundbreaking project is a privilege. The goal is to enhance the AM landscape and substantially reduce the time and cost associated with operational qualification,” said Dr. Taheri-Andani. “Collaborating with brilliant minds, including our alumni like Yash, makes this journey even more rewarding."

Dr. Parikh will support Dr. Taheri-Andani and his research team with expert guidance on a novel data-driven operational qualification approach as well as best practices to expedite it. “Reuniting with my alma mater, Texas A&M University, for such a transformative project is an honor,” said Dr. Parikh. “This collaboration goes beyond innovation; it’s about positively impacting the industry and reinforcing the enduring bond between alumni and the university. This prestigious award is a testament to the unwavering dedication of faculties and students within the Mechanical Engineering Department who are committed to driving innovation and excellence in advanced technologies, including AM. With EOS showcasing its support through a cost-sharing pledge, I am excited to embark on this journey as one of the research partners and dedicated to demonstrating a steadfast commitment to realize the desired production results for customers and the AM community at large.”

This collaborative effort brings together a comprehensive skilled team, including research partners from the University of Michigan and two AM companies — Addiguru, LLC, and Beehive Industries — all contributing their expertise to the project.

Additionally, this project will receive support from Freemelt, a company providing Electron Powder Bed Fusion (E-PBF) equipment and services, leveraging the open-source and cutting-edge E-PBF system, FreemeltONE. Daniel Gidlund, CEO, stated, "Working together with Dr. Taheri-Andani, the project aims to push the boundaries of qualification in metal AM, which is a critical aspect for AM industrialization. We are very glad and excited to support and be engaged with Texas A&M Engineering Experiment Station under this critical America Makes project.”

“I am committed to advancing AM and highlighting the importance of collaborative research and industry-academia partnerships,” said Dr.Taheri-Andani. “This project, aimed at streamlining operational qualification, is poised to make a significant impact on the efficiency and cost-effectiveness of AM processes.” 

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