Amal Charles

Amal Charles
Karlsruhe Institute of Technology | KIT · Institute for Automation and Applied Informatics

Master of Science
Researcher in Metal Additive Manufacturing

About

21
Publications
12,645
Reads
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219
Citations
Introduction
Doctoral Researcher with a focus on process development of metal additive manufacturing processes. Recipient of a Marie Curie Research fellowship. Understanding the underlying multiphysical and multiscale behaviour of AM processes is vital, I accomplish this through advanced simulation and experimentation. My special interest is on developing bespoke parameters for intricate features and complex geometries.
Additional affiliations
July 2017 - present
Karlsruhe Institute of Technology
Position
  • Research Associate
June 2017 - September 2020
Karlsruhe Institute of Technology
Position
  • PhD Student
Education
July 2017 - December 2020
Karlsruhe Institute of Technology
Field of study
  • Additive Manufacturing
September 2014 - November 2016
KTH Royal Institute of Technology
Field of study
  • Production Engineering and Management
July 2010 - May 2014
VIT University
Field of study
  • Mechanical Engineering

Publications

Publications (21)
Article
Full-text available
The rise in popularity of Additive Manufacturing technologies and their increased adoption for manufacturing have created a requirement for their fast development and maturity. However, there is still room for improvement when compared with conventional manufacturing in terms of the predictability, quality, and robustness. Statistical analysis has...
Article
Full-text available
Down-facing surfaces are one of the most challenging features in metal parts produced by laser powder bed fusion (LPBF). A combination of reasons, primary of which are residual stresses and overheating cause these features to have the worst surface finish and dimensional accuracy of all LPBF surfaces. In order to examine this phenomenon, a Design o...
Chapter
Full-text available
The dawn of mainstream electric vehicles is here, with almost all major automotive manufacturers now offering fully electric alternatives to traditional internal combustion-based cars. This is in alignment with major trends in sustainability in today’s world where a reduction in the usage of fossil fuels and other fossil fuel-dependent technologies...
Article
Full-text available
Dross formation is a phenomenon that is observed while printing metallic components using Laser Powder Bed Fusion (L-PBF) and occurring primarily at down-facing surfaces that are unsupported and suffer inadequate heat removal. Naturally, dross formation causes dimensional inaccuracy, high surface roughness and also adversely affects the mechanical...
Article
Full-text available
The aim of this project is to demonstrate a proof of concept by using Additive Manufacturing (AM) technology in order to demonstrate its viability for the production of tailor-made components with regions of varying (higher and lower) hardness and surface roughness within a single part. In order to do this, first a test piece is designed and printe...
Conference Paper
Additive Manufacturing (AM) technologies are creating pathways for a digital transition in manufacturing and the Laser Powder Bed Fusion (LPBF) process remains the most promising and successful technology in this regard. This has inspired research and development efforts to further capabilities and to push the state of the art in order to open up e...
Poster
Full-text available
In early 2020 the COVID-19 pandemic revealed massive shortages in short term supply of personal protective equipment. Drastically rising demands, panic buying, and disruption of established global supply chains in some countries, including Germany, resulted in a need for quick, innovative and easy to apply solutions. A coalition of enthusiastic mak...
Article
Full-text available
This paper presents a concept for an integrated process chain for tooling production based on metal additive manufacturing. The proposed approach aims at taking advantage of a fully digitized production line, describing the main steps for the synergetic integration of the manufacturing assets. The production line entails digital infrastructure that...
Chapter
Full-text available
Additive Manufacturing (AM) technologies have recently gained significance amongst industries as well as everyday consumers. This is largely due to the benefits that they offer in terms of design freedom, lead-time reduction, mass-customization as well as potential sustainability improvements due to efficiency in resource usage. However, convention...
Article
Full-text available
The eruption of the severe acute respiratory syndrome coronavirus 2 (SARS-CoV-2) (corona virus disease, COVID-19) in Wuhan, China, and its global spread has led to an exponentially growing number of infected patients, currently exceeding over 6.6 million and over 390,000 deaths as of the 5th of June 2020. In this pandemic situation, health systems...
Conference Paper
Although there have been numerous attempts to define how different laser polishing parameters affect the generated surface roughness, there has been no detailed investigation of how their effects can be combined to optimize the process. This paper applies statistical analysis to model and predict the resulting surface roughness for laser post-proce...
Conference Paper
Full-text available
Laser-based powder bed fusion (L-PBF) is one of the AM techniques that has continued to gain an increased market acceptance and penetration, particularly in a wide range of industrial applications that include automotive, aerospace, medical/dental and robotics. However, in spite of its unstoppable rise in popularity, the L-PBF process still poses s...
Conference Paper
Full-text available
The growing rise of popularity of Additive Manufacturing technologies and its increased adoption for manufacturing has created a requirement for its fast development and maturity. However, it still lags far behind conventional manufacturing in terms of predictability, quality and robustness. Statistical modelling has proven to be an excellent tool...
Chapter
Full-text available
Although additive manufacturing (AM) has offered proven ability to reduce waste when compared with traditional manufacturing techniques, however, AM processes such as fused filament fabrication (FFF) still poses some negative environmental and economic aspects in terms of generated waste. This waste comes from rafts, supports, or bases that are par...
Article
Full-text available
Featured Application: This paper presents the first investigations towards closed loop feedback control of the selective laser melting (SLM) process. Insight gained from this work can be applied to facilitate in-process optimization of the SLM process for maximizing part quality and minimizing surface roughness. Abstract: Additive manufacturing pr...
Conference Paper
Full-text available
Additive manufacturing provides a number of benefits in terms of a large freedom to design complex parts and reduced lead-times while globally reducing the size of supply chains as it brings all production processes under one roof. However, AM lags far behind conventional manufacturing in terms of surface quality. This proves a hindrance for many c...
Conference Paper
Full-text available
Additive manufacturing has recently emerged as a flexible fabrication method of complex geometry designs. Fused Filament Fabrication (FFF) is a 3D printing technique to print complex features and can be used in the manufacturing of complex shapes of products in a cost-effective manner. However, its competency to produce precise products with high d...
Conference Paper
Full-text available
PAM^2, which stands for Precision Additive Metal Manufacturing, is a European MSCA project in which 10 beneficiaries and 2 partners collaborate on improving the precision of metal Additive Manufacturing. Within this project, research is done for each process stage of AM, going from the design stage to modelling, fabricating, measuring and assessmen...
Conference Paper
Full-text available
Additive Manufacturing (AM) technologies have rapidly spread to cover a wide range of industrial applications, such as aerospace, automotive and biomedical. This is due to their inherent capability to produce parts with complex geometries in short lead times, which shows great potential to strengthen the profitability of supply chains. However, one...

Questions

Question (1)
Question
Metal AM/3D Printing processes have seen massive R&D efforts over the last few years, which have helped improve the indsutrialisation efforts of AM processes. I would be very interested to hear everyone's thoughts on what the topics are, that need to be investigated and developed over the next 5 years by those in research.

Network

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Projects

Project (1)
Project
The overall objective of PAM^2 is to ensure the availability of high precision Additive Manufacturing processes and (computational) design procedures. Detailed objectives to reach this overall goal are: 1. to develop advanced (computational) design tools, enabling competitive designs, better use of AM possibilities against minimal design costs and reduced time-to-market 2. to develop better modelling tools for first-time-right processing 3. to optimise selective laser melting process strategies for improved part precision and feature accuracy 4. to understand the link between post-process metrology and in process observations, creating the basis for in-process quality control and process stability 5. to develop innovative in-process and post-process techniques to reduce or remove roughness, porosity and internal stresses and to improve dimensional accuracy and mechanical properties See also: https://www.pam2.eu