Hardmetals, also known as cemented carbides, have played a huge and often overlooked role in modern industrial development. From the first application in wire drawing dies in the 1920s, hardmetals are today universal and their application areas range from metal cutting and the machining of wood, plastics and composites to the production of glass bottles, aluminium cans and the ubiquitous ball-point pen tip. Can Additive Manufacturing make inroads into a market worth tens of billions of Euros in annual sales? Dr.-Ing. Johannes Pötschke reviews the fundamentals of hardmetal production and considers the most viable AM processes for this complex family of materials. [First published in Metal AM Vol. 6 No. 3, Autumn/Fall 2020]
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Nickel-base superalloys are an important material group for components used in the gas turbine, aerospace and chemical processing industries. Many of the well-established superalloys available today do not, however, adapt well to processing by Additive Manufacturing. In this article, Dr Tatiana Hentrich and Dr Christina Schmidt, VDM Metals International GmbH, present an overview of nickel-base alloys with a focus on strengthening effects, mechanical properties and weldability, comparing production challenges by conventional production routes and Laser Beam Powder Bed Fusion (PBF-LB) Additive Manufacturing. [First published in Metal AM Vol. 6 No. 3, Autumn/Fall 2020]
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The use of metal Additive Manufacturing for the production of injection moulding tools that have been optimised by conformal cooling is growing internationally. For many companies, however, the main obstacles to adoption are not concerns about material properties or apprehension about unfamiliar processes, but simply initial cost – the tooling industry is extremely competitive and AM inserts can be expensive. Here, 3D Systems’ Mark Cook and GF Machining Solutions’ Dogan Basic present a case study from leading toolmaker and injection moulding specialist TK Mold that highlights how such inserts, when efficiently manufactured, can reduce overall manufacturing costs and improve part quality. [First published in Metal AM Vol. 6 No. 3, Autumn/Fall 2020]
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When you mix a childhood obsession with rockets and space travel, a career at some of the biggest global names in aerospace, and a curiosity about hobbyist 3D printing developed through maker fairs, it was inevitable that FormAlloy’s Melanie Lang would end up in the world of metal Additive Manufacturing. Metal AM magazine’s Emily-Jo Hopson-VandenBos interviewed Lang, CEO and co-founder of Directed Energy Deposition (DED) specialist FormAlloy, about her route into AM, her company’s technology and the outlook for the process. [First published in Metal AM Vol. 6 No. 3, Autumn/Fall 2020]
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Whilst Additive Manufacturing is undoubtedly having a huge impact on the design and manufacture of rocket propulsion systems, most notably combustion chambers and nozzles, the Achilles’ heel of most AM processes is as-built surface finish. Whilst in many AM applications surface finish may be largely irrelevant to a component’s function or performance, when it comes to high-cycle fatigue properties, achieving the required level of smoothness is critical to performance. In this article, Justin Michaud, REM Surface Engineering, reports on advancements achieved in this area through a public-private partnership with NASA. [First published in Metal AM Vol. 6 No. 3, Autumn/Fall 2020]
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The story of Atherton Bikes stands out as a shining example of how metal Additive Manufacturing can be successfully embraced and commercialised by a small, dedicated team of people. In the case of the Atherton family, the technology has not only enabled them to maximise their performance at the pinnacle of professional mountain biking, but has also opened a path to commercial bike production in an industry where frame manufacturing is dominated by Taiwan and China. In an article that will appeal to anyone considering the use of metal AM, the Atherton Bikes team shares its experiences with Robin Weston. [First published in Metal AM Vol. 6 No. 3, Autumn/Fall 2020]
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It is far too easy to overuse superlatives when speaking about hypercars or Additive Manufacturing. When the discussion combines both – Bugatti’s new driver-focused Chiron Pur Sport and a high-performance AM component that truly pushes today’s processes to their limits – the result is worthy of a closer look. In the following in-depth case study, Bugatti and APWORKS explain the requirements, development and production of the Chiron Pur Sport’s exhaust finisher and share insight into some of its hidden details, from lattice structures to nature-inspired honeycomb reinforcements. [First published in Metal AM Vol. 6 No. 2, Summer 2020]
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A new wave of AM machine manufacturers focused on Electron Beam Powder Bed Fusion (PBF-EB) is looking to capitalise on what is perceived as a process with significant untapped market potential. One of the most prominent of these newcomers is Freemelt AB, a developer of open source machines designed to help broaden the PBF-EB material portfolio and application areas. As Metal AM magazine’s Emily-Jo Hopson-VandenBos reports, co-founders Ulric Ljungblad and Ulf Ackelid have no doubt as to the opportunities ahead. [First published in Metal AM Vol. 6 No. 2, Summer 2020]
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In January, Boeing’s new 777X aircraft made its maiden flight, powered by two GE9X engines from GE Aviation. Whilst this was a major moment for both companies, it was also a huge milestone for Electron Beam Powder Bed Fusion (PBF-EB), and the culmination of decades of process and material development work at the driving force behind the technology, Arcam AB. Whilst the many turbine blades used in the GE9X engine are the highlight of the first chapter in the story of PBF-EB, there is also a lingering sense of unrealised potential. Here, Joseph Kowen considers the story to date and highlights a new generation of firms working to increase the technology’s adoption. [First published in Metal AM Vol. 6 No. 2, Summer 2020]
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Rich in creativity and rooted in a long artisanal manufacturing heritage, one would imagine that there can be few sectors as perfectly suited to embrace the potential of metal Additive Manufacturing than the jewellery industry. In reality, however, the sector continues to hold back on the full-scale adoption of AM, despite numerous successes. In this article, Michela Ferraro-Cuda considers progress to date in the adoption of precious metal AM in the jewellery industry, and showcases a number of leading designers who have leveraged the technology’s potential for innovation and differentiation. [First published in Metal AM Vol. 6 No. 2, Summer 2020]
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Able to achieve quicker build speeds and lower cost per part than its rival technologies, metal Binder Jetting (BJT) has generated increasing interest and rapid industry investment over the past two years. But while many engineers are now becoming familiar with the principles of design for Powder Bed Fusion AM, design for BJT is less widely understood. In this article, Olaf Diegel and Terry Wohlers attempt to demystify some of the key factors that must be considered when designing parts for BJT. [First published in Metal AM Vol. 6 No. 2, Summer 2020]
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As the metal Additive Manufacturing industry matures at a rapid rate, organisations are now faced with the challenge of scaling their AM operations. Based on a study of 253 companies in a number of sectors, US-based AM software specialist Link3D has developed an ‘Additive Manufacturing Maturity Model’. This simple model can be used as a tool to understand an organisation’s AM maturity whilst also helping them navigate the steps to developing an agile and resilient AM supply chain. Shane Fox, CEO and co-founder of Link3D, explains. [First published in Metal AM Vol. 6 No. 2, Summer 2020]
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