The size of components manufactured by laser powder bed fusion is limited by the available powder bed volume. To create larger structures, additively manufactured components can be combined with intermediate products to increase cost efficiency and amend the requirements. Joints of fiber-reinforced plastic profiles adhesively bonded with laser powder bed fusion manufactured aluminum couplers were investigated as examples. The geometric freedom of design in AM-processes enables optimization of the joint properties: Optimization of the adhesive application. Optimization of the adhesive distribution. Uniform stress distribution within the adhesive fill space. To reveal the adhesive distribution during injection, tests with transparent acrylic models where carried out. The AM components’ topology was optimized using finite element analysis to homogenize the stress distribution within the adhesive. The static strength and fatigue properties were validated experimentally. Results on adhesive distribution and fatigue behavior will be presented.     «

The size of components manufactured by laser powder bed fusion is limited by the available powder bed volume. To create larger structures, additively manufactured components can be combined with intermediate products to increase cost efficiency and amend the requirements. Joints of fiber-reinforced plastic profiles adhesively bonded with laser powder bed fusion manufactured aluminum couplers were investigated as examples. The geometric freedom of design in AM-processes enables optimization of th...     »