Publication Date


Document Type


First Advisor

Majumdar, Pradip, 1954-

Degree Name

M.S. (Master of Science)

Legacy Department

Department of Mechanical Engineering


Mechanical engineering; Engineering


Additive manufacturing widely known as 3D printing is receiving groundbreaking level of attention from industry and research laboratories. The research and development effort has gained tremendous momentum from simple 3D printers to advanced quick manufacturing systems that create functional parts without the need for tooling. While majority of the current 3D printers available in the market build parts using polymeric materials, recent research and development effort is also concentrated on building parts using metals, ceramics, and composites. Electron Beam Melting (EBM), Selective Laser Sintering (SLS), and Selective Laser Melting (SLM) are attractive processes for metallic parts. It is one of the emerging technologies that manufactures three-dimensional objects from a CAD model (e.g. Creo, SolidWorks, CATIA) through an additive process by heating, melting and cooling the deposited materials. The process is repeated in successive layers and is particularly attractive in creating complex shapes with intricate internal geometries. For example, bipolar plates with integrated multiple gas flow and internal cooling channels. A simulation model is essential for establishing all key process parameters for a specific design and material before manufacturing the part. In this study, a three-dimensional computational simulation model will be developed to characterize the Selective Laser Melting (SLM) -- based additive manufacturing (AM) process by laser melting of the pre-deposited particles and forming single layer of the desired part. Analyze the SLM-AM process through iterative refinement of the required beam power. Performing sensitivity analysis for the desired part by heating and melting of spherical particles to establish the optimum operating parameters in terms of the particles size and laser beam power.


Advisors: Pradip Majumdar.||Committee members: Amartya Chakrabarti; John Shelton.||Includes bibliographical references.||Includes illustrations.


viii, 71 pages




Northern Illinois University

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