Articles

Multi-material metal parts by Powder Bed Fusion: New application opportunities

As product developers become more and more aware of the possibilities of metal Additive Manufacturing and the design freedom it offers, metal Laser Beam Powder Bed Fusion (PBF-LB/M) has established itself for series applications in numerous industries. One novel capability of PBF-LB/M which has yet to be fully explored is the production of multi-material metal parts, which would offer huge new potential for designers in many industries. Prof Dr-Ing Christian Seidel looks at methods and solutions for the AM of parts consisting of two arbitrarily distributed metal alloys and presents use cases with the potential for series production by multi-material PBF-LB/M in the near future. [First published in Metal AM Vol. 8 No. 2, Summer 2022] ... Read more »

Fig. 1 Nickel-copper combustion chamber demonstrator parts on the build platform (Courtesy Fraunhofer IGCV)

Additive Manufacturing for oil, gas and maritime: An evaluation of capabilities and potential

In 2018, a consortium of twenty-three companies, managed by DNV and Berenschot, started a project, ProGRAM JIP, to produce a guideline formulating the necessary requirements to introduce components made by Additive Manufacturing into the oil, gas and maritime industry. This was followed, in May 2020, by ProGRAM JIP Phase II, again managed by DNV and supported by Berenschot. The participants in Phase II spanned the entire value chain, from end-users and OEMs to service providers, material suppliers and testing companies. Here, DNV’s Sastry Yagnanna Kandukuri and Berenschot’s Onno Ponfoort present the consortium’s preliminary Phase II findings. [First published in Metal AM Vol. 8 No. 2, Summer 2022] ... Read more »

Fig. 1 Finished impellers manufactured by PBF-EB, one of several metal AM technologies evaluated in Phase II (Courtesy Eureka)

What Xerox’s aluminium liquid metal AM offers for supply chain resiliency

It is too easy to look at metal Additive Manufacturing technologies as neatly fitting into a small number of convenient process categories. The risk, in doing so, is that the best solution could be overlooked. One AM process that does not fit into such neat boxes is Xerox’s Liquid Metal Jetting. Whilst it falls, broadly, under the ISO/ASTM 52900:2015 category of Material Jetting, it is unique among metal AM processes. Here, Bender Kutub considers where it fits into the drive for supply chain resilience, and explores its market potential. [First published in Metal AM Vol. 8 No. 2, Summer 2022] ... Read more »

Fig. 1 The ElemX AM machine, capable of >99% dense aluminium parts using wire feedstock (Courtesy Xerox)

The challenge of grain size:
X-ray powder diffraction analysis of parts made by metal AM

X-ray powder diffraction (XRPD) has long been a powerful tool in metallurgy, but its unsuitability for parts with large grain sizes has made its use for the analysis of metal additively manufactured parts a challenge. In this article, Dr Scott Speakman, Malvern Panalytical, reports on a study in which specimens of soft magnetic Fe-Si steel were made by PBF-LB using a variety of raster and annealing strategies to produce specimens with large grain sizes. The X-ray diffraction data collected illustrates the tell-tale signs of poor crystallite sampling statistics. Speakman presents some strategies for recovering data fidelity with conventionally available options. [First published in Metal AM Vol. 8 No. 2, Summer 2022] ... Read more »

Fig. 1 Malvern Panalytical’s Empyrean range was the X-ray diffractometer platform used in this study

Findings from Wohlers Report 2022: Taking a chance on new technologies and the evolving materials mix

Getting to grips with what is really happening in our industry can be a tricky business. Thankfully market analysis is available from a number of expert sources, with the longest established being the Wohlers Report. Here, Noah Mostow, Olaf Diegel, and Terry Wohlers share insight from the recently published 2022 edition, including an overview of machine sales, the acceptance of a new breed of technology suppliers, the growth of service companies, and the evolving metal AM material mix. [First published in Metal AM Vol. 8 No. 2, Summer 2022] ... Read more »

Fig. 1 Number of metal AM machines sold worldwide from 2003 to 2021 (Wohlers Report 2022)

Transforming access to medical implants: How PrinterPrezz and Additive Manufacturing will improve global healthcare

Some companies have bolder missions than others. Whilst Elon Musk leverages metal Additive Manufacturing to transform space exploration, the founders of PrinterPrezz, Alan and Alexis Dang, Kishore Karkera and Shri Shetty, are aiming to do something equally bold with the same technology: bring safe, affordable, right-fit medical implants to the 97% of the world that can’t currently access them. Todd Grimm interviewed Alan Dang and Shri Shetty to discover more. [First published in Metal AM Vol. 8 No. 2, Summer 2022] ... Read more »

Fig. 1 FDA cleared GAIA lumbar cages manufactured by PrinterPrezz (Courtesy PrinterPrezz)

Anatomy of an AM part failure: Lessons for managers, designers and producers from 2021’s Olympic bike crash

In the men’s track cycling team pursuit qualifying at the 2020 Olympics, broadcast live to a global audience, a handlebar part produced by metal Additive Manufacturing failed with catastrophic consequences for the rider, Australia’s Alex Porter. Six months later, a forensic analysis of the incident was published as a 170-page report. The good news is that the company that made the AM part, along with the technology itself, were cleared of blame. So: what went wrong, and what lessons can be learned? Robin Weston digs into the details. [First published in Metal AM Vol. 8 No. 2, Summer 2022] ... Read more »

Fig. 1 Team Australia's Kelland O'Brien, Sam Welsford, Leigh Howard, and Alexander Porter pictured during the qualifying round of the Men's Team Pursuit at the Tokyo 2020 Olympic Games (Photo credit Shutaro Mochizuki/AFLO/Alamy Live News)

A game of hide and seek with Renishaw and Altair: Artificial Intelligence-powered quality assurance on the fly

Is it possible to actively monitor the huge volumes of data from a Laser Beam Powder Bed Fusion (PBF-LB) machine to identify, through machine learning (ML), build errors as they happen? To answer this question, Renishaw and Altair played a unique game of hide and seek. In this innovative experiment, an error was deliberately hidden in a build for an artificial intelligence (AI)-based solution to find. The hope? True ‘on the fly’ quality assurance for Additive Manufacturing processes for accelerated product development, and dramatically reduced post-production quality checks. [First published in Metal AM Vol. 8 No. 1, Spring 2022] ... Read more »

Seurat Technologies: Evolving AM to finally out-compete conventional manufacturing

Every so often, something comes along that gets the whole Additive Manufacturing industry talking. Over the past two years, few companies have generated as much intrigue as Seurat Technologies, the Lawrence Livermore National Laboratory spin-out named for the French pointillist, bringing with it a technology roadmap that promises to evolve metal AM to the crucial point of out-competing conventional manufacturing methods. In this Metal AM exclusive, James DeMuth, Seurat CEO, offers the deepest look yet into the technology behind his company’s promise. [First published in Metal AM Vol. 7 No. 1, Spring 2022] ... Read more »

Innovation to commercialisation: Atherton Bikes and the journey of an SME bringing AM production in house

Bringing Additive Manufacturing in house is a big step for any company, but when you are at the small end of the ‘SME’ spectrum, it can be an especially bold move. Robin Weston recently visited Atherton Bikes, based in rural west Wales, to see how this specialist bike producer is enjoying ramping up in-house production of its titanium and carbon fibre performance mountain bikes on a new, four-laser Powder Bed Fusion (PBF-LB) machine from Renishaw. [First published in Metal AM Vol. 8 No. 1, Spring 2022] ... 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:

  • Revolution, not evolution: General Motors on building an AM culture and the AM Dream Machine
  • The power of Additive Manufacturing in the hands of artists: Public works to small batch production
  • Growing momentum and broadening recognition: A status update on the rise of Electron Beam PBF
  • Improving carbon capture efficiency through Additive Manufacturing in the race for a liveable climate
  • The System of AM Systems: How Metal Powder Works’ in-process powder production could change metal AM
  • The next generation: Using metal AM to drive emissions reduction and educate the engineers of the future
  • Advances in the AM of refractory metals and hard materials at the 20th Plansee Seminar
  • Additive Manufacturing needs you: Why you and your company should get involved in standards development

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