Ampower investigates potential cost savings offered by metal Binder Jetting and FDM

News
October 25, 2018

October 25, 2018

Ampower investigates potential cost savings offered by metal Binder Jetting and FDM

Ampower’s new report investigates and compares FDM, Binder Jetting and LB-PBF, as well as MIM (Courtesy Ampower)

 

Additive Manufacturing consultancy Ampower, Hamburg, Germany, recently published a study investigating and comparing metal Binder Jetting and Fused Deposition Modelling (FDM) with Laser Beam Powder Bed Fusion (LB-PBF) and Metal Injection Moulding (MIM).

In the study, titled ‘Additive Manufacturing with sinter-based technologies’, Ampower identified current cost reductions of approximately 40%, and future cost reductions of over 80% using the newer Binder Jetting and FDM methods of Additive Manufacturing. However, the report also highlighted some disadvantages of these newer technologies, such as limited material properties which could make them unsuitable for the production of highly-loaded components.

In addition, the complex sintering process involved in Binder Jetting or FDM was found to pose further challenges, such as component distortion. Matthias Schmidt-Lehr, co-author of the study and partner at Ampower, explained, “We expect that, especially in the automotive industry, binder technologies will prevail over high-volume cost-cutting as compared to LB-PBF.”

“Limitations on material properties and process risks can be offset by higher volumes and more complex process development,” he continued. “In demanding industries such as aerospace, industry will continue to rely on  laser and electron beam processes. A short-term reorientation is not to be expected in these industries, especially as many OEMs have already set standards here and invested heavily.”

In addition to the principles of cost structure and material properties, the study also presents guidelines for the design of components for production using Binder Jetting. For the study, more than fifty samples from eight equipment manufacturers were evaluated and, in addition to tensile tests and metallographic density analyses, the surface roughness was measured and a CT analysis of the components carried out.

www.am-power.de

 

Insight from Ampower’s report was featured in the Autumn/Fall 2018 issue of Metal Additive Manufacturing magazine. Read the full article by Ampower’s Maximilian Munsch, Matthias Schmidt-Lehr and Eric Wycisk for free below.

News
October 25, 2018

About Metal Additive Manufacturing magazine

Metal AM magazine, published quarterly in digital and print formats, is read by a rapidly expanding international audience.

Our audience includes component manufacturers, end-users, materials and equipment suppliers, analysts, researchers and more.

In addition to providing extensive industry news coverage, Metal AM magazine is known for exclusive, in-depth articles and technical reports.

Our focus is the entire metal AM process from design to application.

Each issue is available as an easy-to-navigate digital edition and a high-quality print publication.

In the latest issue of Metal AM magazine

Download PDF
 

Extensive AM industry news coverage, as well as the following exclusive deep-dive articles:

  • Metal powders in Additive Manufacturing: An exploration of sustainable production, usage and recycling
  • Inside Wayland Additive: How innovation in electron beam PBF is opening new markets for AM
  • An end-to-end production case study: Leveraging data-driven machine learning and autonomous process control in AM
  • Consolidation, competition, and the cost of certification: Insight from New York’s AM Strategies 2024
  • Scandium’s impact on the Additive Manufacturing of aluminium alloys
  • AM for medical implants: An analysis of the impact of powder reuse in Powder Bed Fusion

The world of metal AM to your inbox

Don't miss any new issue of Metal AM magazine, and get the latest industry news. Sign up to our twice weekly newsletter.

Sign up

Looking for AM machines, metal powders or part manufacturing services?

Discover suppliers of these and more in our comprehensive advertisers’ index and buyer’s guide, available in the back of Metal AM magazine.

  • AM machines
  • Process monitoring & calibration
  • Heat treatment & sintering
  • HIP systems & services
  • Pre- & post-processing technology
  • Powders, powder production and analysis
  • Part manufacturers
  • Consulting, training & market data
View online

Discover our magazine archive…

The free to access Metal Additive Manufacturing magazine archive offers unparalleled insight into the world of metal Additive Manufacturing from a commercial and technological perspective through:

  • Reports on visits to leading metal AM part manufacturers and industry suppliers
  • Articles on technology and application trends
  • Information on materials developments
  • Reviews of key technical presentations from the international conference circuit
  • International industry news

All past issues are available to download as free PDFs or view in your browser.

Browse the archive

Share via
Copy link
Powered by Social Snap