Strategies for advancing the automation of metal Additive Manufacturing

ProcessingSoftware
December 15, 2020

In the early days of metal Additive Manufacturing process development, automation was off the radar of machine manufacturers. Technologies created for rapid prototyping simply had no need for it and, until the last decade, few truly anticipated the pace at which Laser Beam Powder Bed Fusion and Binder Jetting have evolved in the race towards the series production of metal parts. In this article, Joseph Kowen reports on how the industry has addressed the challenges of automation so far, and what developments we can expect in the near future. [First published in Metal AM Vol. 6 No. 4, Winter 2020] ... Read more »

Falcontech: The journey from materials engineering to large-scale metal Additive Manufacturing

China’s Falcontech Co. Ltd. is well on the way to completing its first ‘Super AM factory’, designed to house fifty metal Additive Manufacturing machines supplied by its partner, Farsoon Technologies. Whilst the wider story may take in the dramatic rise of Additive Manufacturing in China over the last decade, at the heart of this ambitious project’s success is the story of a successful partnership between an AM technology supplier and its customer. In this article, Chenlu Fang, Global Marketing Manager of Farsoon Technologies, interviews Shen Yulan, General Manager of Falcontech, and Li Wei, its Sales Director, to tell the story of the company’s rise, its ambitions and the partners’ close collaboration. [First published in Metal AM Vol. 6 No. 4, Winter 2020] ... Read more »

Metal Additive Manufacturing and the new Space Race: The inside track with Launcher and AMCM

In October 2020, New York City-based space technology company Launcher started testing its full-sized E-2 liquid rocket engine, designed to deliver the highest performance at the lowest cost for smaller space launch vehicles. That the E-2 features a one metre tall single-piece copper alloy Laser Beam Powder Bed Fusion (PBF-LB) combustion chamber is remarkable. What is even more impressive is the fact that Launcher, a company with less than twenty employees, achieved this in a short time frame and to a relatively modest budget. Metal AM magazine’s Nick Williams reports on the project and Launcher’s close collaboration with specialist PBF-LB machine builder AMCM GmbH. [First published in Metal AM Vol. 6 No. 4, Winter 2020] ... Read more »

Metal AM in South Africa: Research and commercial initiatives bring the benefit of AM to the African continent

The Additive Manufacturing industry in South Africa has come a long way since the installation of the country’s first AM machine in 1991, with a number of research and commercial initiatives driving the development of world-class applications and knowledge. In this article, Terry Wohlers and Olaf Diegel, Wohlers Associates, present an overview of metal Additive Manufacturing activities in South Africa, from the technology’s life-changing use for medical implants to its development for rapid, large-scale part production and beyond. [First published in Metal AM Vol. 6 No. 4, Winter 2020] ... Read more »

System 3R: Bridging critical gaps in the Additive Manufacturing workflow to enable serial production

Processing
December 15, 2020

In conventional subtractive manufacturing process chains, components move efficiently throughout a production chain using pallets and standard referencing and clamping systems, enabling parts to be automatically processed by a variety of technologies as they move through a facility. GF Machining Solutions’ System 3R division has leveraged its expertise in this area to create a tooling solution tailored to Laser Beam Powder Bed Fusion (PBF-LB) production. As Dogan Basic, Product Manager AM, explains, this optimises workflow, increasing the potential for AM automation and, as a result, for successful series production. [First published in Metal AM Vol. 6 No. 4, Winter 2020] ... Read more »

Machine Learning and Additive Manufacturing: What does the future hold?

ProcessingSoftware
December 15, 2020

As industry marches toward automation, networked communication and robotics, Additive Manufacturing has a unique advantage. No other production technology has been designed, from its inception, to enable connectivity and communication; AM machines around the world are already producing more build data than any other manufacturing technology. If used properly, this data will provide the foundation for the development of Machine Learning tools that can improve and industrialise the AM process at nearly every point in the workflow. In this article, Chelsea Cummings and John Barnes, from The Barnes Global Advisors, discuss the present and future of Machine Learning in AM. [First published in Metal AM Vol. 6 No. 4, Winter 2020] ... Read more »

CFD simulation for metal Additive Manufacturing: Applications in laser- and sinter-based processes

ProcessingSoftware
December 15, 2020

Computational Fluid Dynamics (CFD) is widely applied to solve a broad range of research and engineering problems, from aerodynamics to engine combustion and microfluidics. In this article, Pareekshith Allu, Senior CFD Engineer at Flow Science, Inc, explains how CFD can also be used to improve laser- and non-laser-based metal Additive Manufacturing processes, including Laser Beam Powder Bed Fusion (PBF-LB), Directed Energy Deposition (DED), Binder Jetting (BJT) and Material Extrusion (MEX). [First published in Metal AM Vol. 6 No. 4, Winter 2020] ... Read more »

Metal Additive Manufacturing in New Zealand: An overview of research, commercial activities and strategic initiatives

For a country with a total population significantly smaller than that of cities such as London or New York, New Zealand is ‘punching above its weight’ when it comes to developing expertise in Additive Manufacturing and educating design engineers in how to use it. Olaf Diegel, a professor at New Zealand’s University of Auckland and associate consultant at Wohlers Associates, and Terry Wohlers, president of Wohlers Associates, report on AM activities and highlight a novel range of successful commercial applications. [First published in Metal AM Vol. 6 No. 3, Autumn/Fall 2020] ... Read more »

Neighborhood 91: The bridge to Additive Manufacturing production

Whilst Additive Manufacturing as a technology is proving its worth through an ever growing list of innovative, real-word applications, the obstacles faced by players in the current AM supply chain are numerous, ranging from skills shortages to a highly-complex supply chain, high costs and fluctuating product demand. To address this, Neighborhood 91, an end-to-end AM production campus, is being created in the US city of Pittsburgh that, as Laura Ely and John Barnes report, seeks to condense and connect all components of the Additive Manufacturing supply chain into one powerful production ecosystem. [First published in Metal AM Vol. 6 No. 3, Autumn/Fall 2020] ... Read more »

Additive Manufacturing of hardmetals: An evaluation of potential processes for tool production

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] ... Read more »

High-performance nickel-base alloys for Additive Manufacturing: A review of their limitations and potential

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] ... Read more »

Hybrid inserts for mould and die production: How workflow optimisation can help make the business case for AM

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] ... Read more »

In the latest issue of Metal AM magazine

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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

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