Reliability,  Modelling  & Optimization 
RMO research group
Reliable Design, Materials & Manufactur​ing 

RMO / Research / Reliable Manufacturing 

Reliable Manufacturing

Our research in reliable manufacturing focuses on failure prevention and digital twin modelling at two different scales. i) Product scale, including predicting product performance and quality through detailed analysis and control of the manufacturing process. ii) Production scale, encompassing production planning with emphasizes on resilience to unforseen events.

Defects in additive manufacturing

Defects in additive manufacturing (AM) occur due to a combination of material properties, process parameters, and environmental conditions. These defects can arise from improper laser power, scanning speed, or layer thickness. Common types of defects include porosity, caused by trapped gas or lack of fusion (LOF); residual stresses, which develop due to rapid cooling and can cause warping or cracking; surface roughness, resulting from uneven powder distribution or inadequate layer bonding; and microstructural inhomogeneities, where variations in cooling rates lead to inconsistent mechanical properties. In our research we are particularly focusing on the influence of differenct post-processing techniques, including preloading and Hot Isostatic Pressing (HIP), to help mitigate these defects and improve the quality of AM parts.

Selected representative publications

M. Subasic, M. Olsson, S. Dadbakhsh, X. Zhao, P. Krakhmalev, and R. Mansour, "Fatigue strength improvement of additively manufactured 316L stainless steel with high porosity through preloading," International Journal of Fatigue, vol. 180, p. 108077, 2024.

M. Alzweighi, R. Mansour, A. Maass, U. Hirn, and A. Kulachenko, "Predicting moisture penetration dynamics in paper with machine learning approach," Int J Solids Struct, vol. 288, p. 112602, 2024.

X. Zhao, Y. Wei, R. Mansour, S. Dadbakhsh, and A. Rashid, "Effect of scanning strategy on thermal stresses and strains during electron beam melting of inconel 625: experiment and simulation," Materials, vol. 16, no. 1, p. 443, 2023.

D. Ramanujan, C. Møller, R. Mansour, D. Eheliyagoda, and A. Brandt, "Regenerative Manufacturing: Transforming European Manufacturing Industries Into Competitive, Climate Positive, Material Recirculation Hubs," Aarhus University, 2023. 

Selected representative research projects

 “ACCURATE”: Achieving resilience through manufaCtUring as a seRvice, digitAl Twins and Ecosystems. 3-year funding (2023-2026) from EU HORIZON. Leading a Work-Package.

"Bi0SpaCE": Industry 4.0 Enhanced Digital Product Passports and Circular Economy Dataspaces for Sustainable Bio-Base Industries. 3-year funding (2025-2028) from EU HORIZON. Leading a Work-Package. 

"​MUSTANG 5.0": Transitioning Multistage Stator Manufacturing to Industry 5.0. 3-year funding (2025-2028) from Innovation Fund Denmark. Co-PI.