Selective laser melting (SLM) struggles to produce curved geometries due to stair-step artifacts and dimensional errors. This study integrates SLM with contact-free laser forming (LF) to accurately shape AlSi10Mg sandwich panels containing Kelvin cell cores. Flat SLM panels with 75% porosity (0.9 mm struts) and 85% porosity (0.7 mm struts) were bent via single and multi-line LF. Single line trials showed the 85% core reached a 10° bend after 80 passes, while the 75% core plateaued at 6°. Results of computed tomography scans and finite element simulations indicated bending is driven by top face sheet upsetting and a through-thickness temperature gradient, preserving core integrity. Leveraging these findings, a multi-line LF strategy formed flat panels into a cylindrical geometry (radius ≈ 243 mm, rise ≈ 12 mm) with high geometric accuracy. Three-point bending tests demonstrated that laser-formed curved specimens exhibit higher ultimate strain and energy absorption than directly printed curved specimens, due to recrystallization-induced grain refinement and lower dislocation density. LF’s die-less approach and rapid setup suit small batch, high-value prototyping. The hybrid SLM–LF process thus offers a tool-free route to fabricate lightweight, impact-resistant curved components for aerospace, automotive, and defense sectors.
Changdar et al. (Tue,) studied this question.