Additive Manufacturing

Case study

• practical use is shown in the production of lightweight clamping jaws for drop machine

Technologies and equipment used

DED (Directed Energy Deposition) – metal printing

Directed energy deposition is a technological process in which the fed material is melted directly at the desired location using a laser beam.

InssTek MX600 - DED technology

The InssTek printer uses the so-called Powder-based DED method, where powder is injected into the laser-exposed area and is carried away by an inert gas.

Parameters

• 2kW fiber laser
• 5-axis movement
• Working press 450x600x350mm
• SDM800 (beam diameter 800 µm, layer height 250 µm)
• SDM1600 (1600 µm beam diameter, 600 µm layer height)
• SDM2400 (beam diameter 2400 µm, layer height 900 µm)
• Up to 4 materials at a time
• 3-axis printing capability with preheating to 500°C with 150x150x150mm part size

InssTek MX-LAB – DED technology

Parameters

• 0.5kW fiber IR laser
• 3-axis movement
• Working press 150x150x150mm
• SDM400 (beam diameter 400 µm, layer height 150 µm)
• Up to 4 materials at a time
• Protective atmosphere for the entire chamber

Materials

• Stainless steels - 316L, 431L, 420, N700, 15-5PH, 17-4PH, SAF2507, P21 and others
• Tool steels - H13, S2, M2, T15, MS1, 440C
• Titanium – CP Ti, Ti-6-4, Ti-5-5-5-3, Ti-6-2-4-2
• Nickel – IN625, IN713, IN718, IN738, IN780, Hastelloy X, Nimonic 80A
• Cobalt – CoCr F75, Stellite 6, Stellite 21, Stellite 25
• and other

Meltio + Fanuc – Wire-Laser metal 3D printing

The Meltio printer uses the Wire-based DED method, where a wire is fed into the laser-exposed area.

Parameters

• 6x 200W laser bundle
• Coaxial guided wire
• Working area 500x500x1500 mm, larger parts are possible upon consultation
• Head mounted on 6-axis robot + 2-axis table with 500 kg capacity
• Wire diameter 0,8 - 1,2 mm

Materials

• 316L, ER70S, JC100, 17-4PH, H11, 1.4718, 1.2567, IN718, MoNiCr, Ti6Al4V

LPBF (Laser Powder Bed Fusion) – metal printing

An even layer of powder is applied to the vertically adjustable table and then the area corresponding to the cross-section of the desired piece is melted by a laser beam. Gradual application of individual cuts achieves the desired shape.

Aconity TWO – PBF technology

Parameters

• 2x 1kW nLight SM fiber laser
• Building space dia.400x400 mm
• Reduced chamber dia.140x120 mm
• Layer thickness: from 30 μm to 120 μm
• Minimum x/y resolution: 80 μm (up to 500 μm)
• Double-sided powder deposition
• Preheating 500°C for dia.350x200 mm and reduced chamber

Materials

• 316L, 1.2709, AlSi10Mg, Ti6-4, CuCr1Zr, CoCrMo, IN718, H11

Binder Jetting Technology

Binder Jetting is a technology in which (metal) powder is spread into thin layers and selected areas are selectively bonded using a binder applied by a piezoelectric print head. The result of printing is a so-called "green part," i.e., a part with sufficient strength for handling, which then undergoes heat treatment. Unlike DED and PBF technologies, no melting of the material occurs during printing.

 Parameters

• PMotion system: 3-axis motion (X, Y – print head, Z – powder bed lift)
• Working area: 160 x 60 x 60 mm (W x D x H)
• Print resolution: 1200 x 1200 dpi (print head)
• Layer thickness: 20–150 µm

Materials

• 316L, 17-4PH, M2, IN625, IN718, ceramics

FDM (Fused Deposition Modeling) – plastic printing

This is the most available method of 3D printing, where a plastic string is melted and this melt is extruded by a nozzle and gradually laid by lining into individual layers.

miniFactory Ignite

• Working space 400x600x400 mm
• Version with two nozzles, the second one can be used for supports
• Layer thickness 0.1-0.3 mm for 0.4 mm nozzle
• Nozzles: 0,4; 0,6; 1,0 mm
• Preheating of the working chamber up to 200 °C
• Chamber heating for fillets
• Materials: ABS, ASA, PC, PA6, PA11, ULTEM 9085

Průša XL

• Working space 360x360x360 mm
• Version with two printing heads, the second can be used for supports
• Layer thickness 0.1-0.3 mm for 0.4 mm nozzle
• Materials: PLA, PETG, ASA, ABS, FLEX, PC Blend, and more