DESIGN OF AN ADDITIVE MANUFACTURING SYSTEM FOR PRODUCING DEFENSE-ORIENTED METAL COMPONENTS
DOI:
https://doi.org/10.56132/2791-3368-2026-1-65-102-114Keywords:
Selective Laser Melting, additive manufacturing, energy density, thermal modeling, porosity, defense-oriented components, optimizationAbstract
This study presents a conceptual design and analysis of an additive manufacturing system based on the Selective Laser Melting (SLM) process, with a focus on the optimization of process parameters and thermal behavior. The research addresses the critical challenge of achieving stable melting conditions, minimizing defect formation, and ensuring high mechanical performance of fabricated components. An integrated framework combining system architecture, process parameter analysis, and thermal modeling is proposed. The influence of scanning speed and energy density on mechanical properties, porosity, melt pool characteristics, and residual stress is investigated. The results demonstrate that optimal process conditions, particularly within a scanning speed range of 600-800 mm/s and energy density of 60-90 J/mm³, provide a balanced combination of strength, ductility, and structural integrity. Thermal field analysis reveals the presence of localized heating, steep temperature gradients, and heat accumulation effects, which significantly influence microstructure formation and process stability. The findings confirm that controlled energy input and optimized thermal conditions are essential for reducing defects and improving the quality of SLM-produced components. The proposed approach is particularly relevant for the production of defense-oriented metallic components requiring high reliability and structural integrity. The study provides a theoretical basis for further experimental validation and practical implementation in advanced manufacturing systems.
Downloads
References
1. Akula S. B. et al. Fuzzy MCDM-Based Selection of 3D Printed Lattice Architectures for Underbody Blast Protection in Armored Vehicles //Journal of Materials Engineering and Performance. - 2025. - С. 1-29. https://doi.org/10.1007/s11665-025-12708-y
2. Zhang Y., Fu Y., Xu J. A 3D-Printed Ka-Band Waveguide Duplexer //2025 International Conference on Microwave and Millimeter Wave Technology (ICMMT). – IEEE, 2025. - С. 1-3. https://doi.org/10.1109/icmmt65948.2025.11188497
3. Ayan M. A., Cakir S. Strategic Foresight for Emerging Defense Technologies: Impact on STI Policies and Diffusion Timelines Across Short, Medium, and Long‐Term Horizons //Futures & Foresight Science. - 2025. - Т. 7. - №. 3. - С. e70024. https://doi.org/10.1002/ffo2.70024
4. Veera Siva Reddy B. et al. Additively Manufactured AlSi10Mg Lattices for High-Performance Sabots //Dola and C, Chandrasekhara Sastry and ES, Suraj and Gari, Subba Reddy Nagireddy and S, Suryakumar, Additively Manufactured AlSi10Mg Lattices for High-Performance Sabots. https://doi.org/10.2139/ssrn.5408048
5. Kreusch Filho D. et al. Graphene-Based Sensors and Biosensors Fabricated via Pulsed Laser Deposition for Chemical and Biological Threat Detection: A Comprehensive Roadmap //Sensors. - 2026. - Т. 26. - №. 4. - С. 1214. https://doi.org/10.3390/s26041214
6. Yadav S. V. et al. Next-generation compact antenna for robust defense and CubeSat communication //Scientific Reports. - 2026. https://doi.org/10.1038/s41598-026-37874-4
7. Hellberg R. Achieving Security of Supply in a Defense Context //Advanced Topics in Defense Project Management. - Bentham Science Publishers, 2026. - С. 41-74. https://doi.org/10.2174/9798898811808126020006
8. Roshan M. et al. A review on fatigue characteristics of nickel‐aluminum bronze (NAB): conventionally fabricated and additively manufactured //Fatigue & Fracture of Engineering Materials & Structures. - 2025. - Т. 48. - №. 2. - С. 535-565. https://doi.org/10.1111/ffe.14499
9. Tan F., Satı O. V. Determination of Optimal Reinforcement Ratios for Injection Molded Engineering Components: A Numerical Simulation //Polymers. - 2025. - Т. 17. - №. 20. – С. 2793. https://doi.org/10.3390/polym17202793
10. Jadhav G., Kandasubramanian B., Kulkarni A. PPS Matrix Composites With Carbon-Reinforced Fillers for Enhancing EMI Shielding Efficiency //Polymer-Plastics Technology and Materials. - 2025. - Т. 64. - №. 16. - С. 2557-2575. https://doi.org/10.1080/25740881.2025.2555986
11. Tulegulov A.D., Yurkov N.K. Additive technologies for the creation of metal objects for military equipment and armaments. Bulletin of the Academy of the National Guard of the Republic of Kazakhstan. 2024.- No. 3(53).- P.151-157. https://doi.org/10.56132/2791-3368.2023.1-49-01
12. Jumagaliyeva А., Abdykerimova Е., et al. (2025). Аpplication of deep learning methods to visual pattern recognition in heterogeneous images. KazATC Bulletin, 141(6), 195–208. https://doi.org/10.52167/1609-1817-2025-141-6-195-208
13. Tulegulov, A., et al. The use of cad and cae information technologies in additive manufacturing. Vestnik KazUTB, vol. 2, no. 27, June 2025, https://doi.org/10.58805/kazutb.v.2.27-978
