BLT unveils high-precision metal PBF-LB technology for micro-sized parts
August 21, 2024
Xi’an Bright Laser Technologies Co., Ltd (BLT), based in Xi’an, China, has announced the development of a high-precision Laser Beam Powder Bed Fusion (PBF-LB) metal Additive Manufacturing process for the production of micro-sized parts. The new process is reported to be capable of achieving surface roughness as low as Ra 2-3 μm and precision below 0.05 mm.
BLT explains that traditional metal PBF-LB technology generally excels at producing parts with larger feature sizes, where surface roughness ranges from 5-20μm and manufacturing precision is above 0.1 mm. Recognising the growing demand for smaller and more precise components, the BLT team embarked on a multi-year project to optimise equipment, processes, software, and raw materials.
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To demonstrate the capabilities of this technology, the BLT team used algorithmic digital design to create an F-RD topology structure model. The F-RD structure is a type of periodic minimal surface characterised by distinct hyperbolic features and complex curvature variations. With principal curvature radii ranging from approximately 0.5 mm to +∞ (straight line), the algorithm-generated model exhibits rich curvature dynamics. The final formed part showcases the effects of different inclinations on the local surface texture within the same layer thickness.
By comparing parts formed with traditional 60 μm, 40 μm, and 20 μm layers against those produced with BLT’s 10 μm high-precision metal PBF-LB technology, the results were striking. The surface quality improved significantly, with roughness decreasing from Ra 7 μm, 6 μm, and 5 μm to Ra 2.6 μm. The high-precision parts exhibited a smooth, refined surface free from the layer lines typically associated with Additive Manufacturing.
BLT’s high-precision metal PBF-LB technology has reportedly already been successfully applied in various industries, showcasing its versatility and effectiveness. These include the following components:
Case Study 1: Medical component
This medical structural component has a maximum diameter of 3 mm, with eight 0.3 mm fluid channels and a minimum wall thickness of 0.09 mm between them. Traditional metal PBF-LB technology is unable to achieve the precision required for such intricate internal channels. Utilising BLT’s high-precision metal PBF-LB technology, the part was successfully manufactured with all fluid channels intact and no wall breaches. The dimensional accuracy deviation was within 0.05 mm, meeting stringent quality standards and eliminating the risk of cracks or deformations during use.
Case Study 2: Advanced structural component
In collaboration with the MicroNeuro project team, BLT developed an advanced structural component with a minimum wall thickness of just 0.15 mm. Traditional manufacturing faced difficulties in positioning, processing, and stability. BLT’s high-precision metal PBF-LB technology overcame these challenges, significantly reducing development time, lowering material costs, and improving material utilisation efficiency. The resulting parts exhibited superior surface finish and flatness, meeting all surface roughness requirements and ensuring consistent quality in batch production.
Case Study 3: Stainless steel threaded part
This stainless steel threaded part with a minimum thickness of 0.1 mm and a forming angle of 30° posed a challenge for conventional metal PBF-LB methods, which required additional support structures for the threads. BLT’s high-precision metal PBF-LB technology successfully formed the part without the need for support structures, achieving a surface roughness of Ra≤1.6μm through simple sandblasting.
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