Structural Integration of Sensors/Actuators by Laser Beam Melting for Tailored Smart Components

Laser beam melting (LBM), an additive laser powder bed fusion technology, enables the structural integration of temperature-sensitive sensors and actuators in complex monolithic metallic structures. The objective is to embed a functional component inside a metal part without losing its functionality by overheating. The first part of this paper addresses the development of a new process chain for bonded embedding of temperature-sensitive sensor/actuator systems by LBM. These systems are modularly built and coated by a multi-material/multi-layer thermal protection system of ceramic and metallic compounds. The characteristic of low global heat input in LBM is utilized for the functional embedding. In the second part, the specific functional design and optimization for tailored smart components with embedded functionalities are addressed. Numerical and experimental validated results are demonstrated on a smart femoral hip stem.