Additive Manufacturing Systems

Wind of Change May Reroute the Future of Electric Cars

Reduced gas spending and environmental impact are big with electric cars. But instead of refilling, the need to pull over for recharging has still limited them. What if that changed? Take a closer look at a new concept that is pushing the limits of what is known today.
Additive Manufacturing Systems: Articles

Complexity Comes for Free

Here is the SLM 500HL quad-laser powder bed fusion system in operation. Note the build chamber during the process, where you can see the lasers hitting the powder bed and melting the powder into the previous layers of the designed geometry. To make a turbine blade with conformal cooling channels out of a nickel-based alloy previously took two hours and 15 minutes on a medium sized, single laser machine. But now, with increased machine build envelopes and four lasers building simultaneously, the average processing time can be reduced to 35 minutes – an improvement that halves the costs per part.
Producing metal parts in a powder bed fusion process is proving to be a game changer in the energy sector, where it generates new opportunities to produce previously impossible geometries in internal cooling channels or undercuts that are used in all sorts of heat exchangers and turbine generator systems.

The Largest Qualified 3D Metal Part for European Aerospace is Here

3D printed by powder-bed-based laser melting, Europe’s largest additively manufactured part in orbit is an antenna support for satellites made of aluminum with dimensions of 447 x 204.5 x 391 mm3, excluding the height of build plate. (first view)
How do you economically produce huge parts with intricate geometry that has a tendency to warp but must withstand critical applications in a demanding environment? Here’s the answer.

A Unique Partnership: Metal Additive Manufacturing and Conventional Machining

Metal AM lowers total cost by creating highly intricate components that eliminate assemblies, are lighter and possess increased structural capabilities and product durability that perform at higher efficiencies and temperatures. Here is a lightweight combustion chamber for a European Space Agency communication satellite engine incorporating mesh geometry for advanced structural and thermal performance.
Here are five important aspects of the design and manufacturing process that everyone should understand to properly and successfully implement metal additive manufacturing within your company.

Additive Manufacturing: Making Sense of Laser Metal Deposition and 3D Printing

Traditional manufacturing processes alter forms through material removal, heat or mechanical force. But in generative or additive manufacturing, structures are built up layer by layer. Laser additive manufacturing, electron beam melting and laser metal deposition are all types of additive manufacturing processes.
Because metal additive manufacturing processes are complex and require extensive material and process knowledge, it can be difficult for a metal fabricator to see how or when 3D printing might fit. To help make sense of it all, let’s consider the basics of additive manufacturing and 3D printing and how it all relates to metal fabrication.

Veterinary Medicine Adopts 3D Metal Printing

The perfectly fitting beak prosthetic was secured in place on the bird with bone cement and colorful rhinestone-styled orthopedic screws. The bird was able to try out the beak within 48 hours and made a full recovery while awaiting placement at a zoo. (first view)
The durability and strength of metal, coupled with a nimble approach to product development and reduced lead times, are driving the widespread adoption of metal additive manufacturing for orthopedic care and prosthetics. Here is one example where 3D metal printing recently proved to be a truly lifesaving process.


Additive Manufacturing Systems: Industry News

3D Printing the Most Powerful Magnets on Earth

Magnet Applications and ORNL have 3D printed NdFeB magnets that outperform traditional bonded magnets, and with less waste.

TRUMPF and Siemens Partner on Metal AM Technology

They are developing software that streamlines the design and preparation of metal parts that are 3D printed using laser metal fusion.

Oerlikon to Build Advanced Manufacturing Facility in U.S.

This site will produce titanium alloys for additive manufacturing and certain high-end thermal spray powders.


Additive Manufacturing Systems: Products

3D Printing Metal Parts Quickly and Flexibly

Booth C-35041: Ideal for job shops, medical or dental operations, or R&D environments, the compact TruPrint 1000 laser metal fusion system from TRUMPF can economically produce individual pieces or short production runs of parts with complex geometry, such as those with internal channels and hollow spaces.
The TruPrint 1000 laser metal fusion system from TRUMPF is a perfect fit for job shops, medical or dental customers, or for R&D environments.

IMTS 2016: Additive Manufacturing

Booth N-71: The metal-based SLM 280HL Selective Laser Melting additive manufacturing system from SLM Solutions combines an increased build envelope with dual laser technology, faster bi-directional recoating, open software controls and closed-loop powder handling to be the fastest machine in its class for building complex and completely dense metal parts.
Additive manufacturing enables layer-by-layer processes to fabricate three-dimensional products. See the continued improvements in materials and processes that are producing more industrial additive solutions than ever.

3D Print Head Adapter for CNC Machines

Booth S-8319: The new spindle-powered wireless 3D Print Head from Hurco extrudes plastic PLA filament to transform WinMax part programs on a CNC vertical machining center into 3D printed rapid prototypes directly on the machine. There are no wires to install so it can easily be moved to other Hurco machining centers within a shop.
The spindle-powered wireless 3D Print Head from Hurco enables shops with no solid modeling experience to transform their WinMax part programs into a 3D printed rapid prototype directly on their CNC machine.