SHL (UAM)

Sheet Lamination / Ultrasonic Additive Manufacturing

ISO/ASTM Sheet Lamination family. Thin metal foils or sheets are bonded layer by layer via ultrasonic friction welding and trimmed by CNC.

ISO Process Families Technology Finder Material Matrix Technology Comparison

Operating Principle & Process Flow

Operating Principle: A sonotrode presses metal foils together and bonds them via high-frequency ultrasonic vibrations in a solid state.

Process Flow: Foil placement -> Ultrasonic welding -> CNC contour milling -> Repeat.

Technical Specifications

Energy Source: Ultrasound / kinetic friction (no melting).
Feedstock / Material Feed: Metal foils / sheets.
Typical Part Size: Medium to large.
Build Rate: Medium.
Accuracy: Very high (as each layer is CNC-machined).
Surface Quality: Very good (due to CNC finishing of flanks).

Applications & Materials

Typical Materials: Aluminium, copper, steel, titanium.

Typical Applications: Embedding sensors, smart structures, multi-material heat exchangers (Cu/Al).

Industries: Research & development, aerospace.

Advantages

Solid-state process: no melting occurs, no solidification stresses. Outstanding for embedding electronics/sensors directly into solid metal.

Disadvantages / Limitations

Disadvantages: High material waste (scrap sheet trimming), anisotropic strength (Z-axis often weaker).

Limitations: Internal cavity complexity limited (support removal from foil cavities is not possible).

Economics

Highly niche. Economical only when sensor integration into solid metal is required.

ISO/ASTM Classification

Only ISO/ASTM process operating entirely in the solid state at room temperature.

Related Whitepapers & Technical Articles

Ultrasonic Additive Manufacturing (UAM)

Metal 3D printing without heat: How sound waves weld foils and embed electronics.

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Machine Mediation

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Orientation for Custom Component Requirements

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