In May this year, GE held its first ‘Industry in 3D’ event, gathering several hundred international participants from the world of business to discover the current status of Additive Manufacturing and the opportunities that it presents to industry. Whilst the technology has come on rapidly in recent years, GE recognises that there is still a long way to go to convince many business leaders that ‘the time is now’ for its wider adoption. As Metal Additive Manufacturing magazine’s Nick Williams reports, this event sought, through GE’s story and those of its partners and customers, to make the case for AM [First published in Metal AM Vol. 4 No. 2, Summer 2018]
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In a little over ten years, France’s Poly-Shape has grown into one of Europe’s leading manufacturers of AM components. With more than thirty metal AM systems installed across four plants, the company is a key supplier to top-tier motorsports, from Formula 1 and IndyCar to World Rallycross and the Pikes Peak International Hill Climb. In the following article, the company presents a series of case studies highlighting the use of metal AM in this sector, and reveals its approach to the technology and plans for the future [First published in Metal AM Vol. 4 No. 2, Summer 2018]
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LPW Technology, a provider of ultra-clean metal powders for Additive Manufacturing, recently celebrated the official opening of its new purpose-built metal powder manufacturing facility in Widnes, Cheshire, UK. The result of a £20 million investment, the company expects that this new plant will be capable of producing around 1,000 tonnes of gas atomised alloy powders per annum, with complete digital integration of manufacturing control processes. Bernard Williams, Consulting Editor at Metal AM magazine, reports on his visit to the official opening of the 9,700 m2 plant and tour of the new facility. [First published in Metal AM Vol. 4 No. 2, Summer 2018]
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As the Additive Manufacturing industry grows, so does the number of metal powder suppliers and the range of different powder types that are available. In the following article Toby Tingskog presents a beginners’ guide to understanding metal powders for Additive Manufacturing. Topics include powder manufacturing processes, spherocity, chemistry and measurement technologies, as well as considerations in relation to heats, lots and batches. As such, it is hoped that this review will allow for a clearer understanding of powder properties and reduce confusion among end users [First published in Metal AM Vol. 4 No. 2, Summer 2018]
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Designing a component for AM whilst taking advantage of all the opportunities that the technology presents can result in many variables. Even a group of experienced Design for Additive Manufacturing (DfAM) experts will end up with significantly different build strategies for an identical part. In the following article, Olaf Diegel and Terry Wohlers consider how software innovations could further streamline the AM process, from part positioning and stress management to surface finish considerations and quality control
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A number of factors drive the selection of process parameters in Laser Powder Bed Fusion (LPBF). In this invaluable resource Marc Saunders, Renishaw plc’s Director of Global Solutions Centres, details how these parameters define the ‘operating window’ in which AM users must work, and offers advice on identifying the ideal process parameters for metal AM parts. The sensitivity of the process to changes in part geometry is also considered, along with how this may drive part developers towards application-specific parameter choices [First published in Metal AM Vol. 4 No. 2, Summer 2018]
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As the new Formula 1 season gets underway, Additive Manufacturing will have played a vital role in the development and manufacture of the cars on track. Metal AM magazine’s Nick Williams recently visited Sauber Motorsport AG at its headquarters near Zürich, Switzerland, and discovered how a partnership with Dutch AM technology supplier Additive Industries has supported both the development of in-house AM applications and an expansion of Sauber Motorsport’s AM services for third parties [First published in Metal AM Vol. 4 No. 1, Spring 2018]
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Sweden’s Digital Metal® has enjoyed a significant increase in its profile over the last year. This was achieved, in part, by a major brand relaunch, but more significant was the move to begin selling its machines to third parties, rather than offering AM component manufacturing solely in-house. Metal AM magazine’s Emily-Jo Hopson reports on the evolution of the company, its unique approach to developing its technology and the benefits of being owned by the world’s largest producer of metal powders [First published in Metal AM Vol. 4 No. 1, Spring 2018]
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One of the goals for the metal Additive Manufacturing industry is the automated series production of components through a streamlined manufacturing process. Such an ambitious goal faces a major obstacle: the challenge of powder removal. Joseph Kowen reviews some of the significant risks facing AM producers at this stage of the process, from health and safety considerations to the impact on quality and productivity, and highlights some of the technologies being developed to address them [First published in Metal AM Vol. 4 No. 1, Spring 2018]
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The formnext powered by TCT exhibition, held from November 14-17, 2017, in Frankfurt, Germany, featured a parallel four-day conference that addressed a wide range of issues of relevance to the Additive Manufacturing community. Besides technical and application innovations, a whole day of the conference was devoted to business considerations and expectations relating to the future development of the AM industry. In this exclusive report for Metal AM magazine, Dr Georg Schlieper highlights a number of key business-related considerations for the future of the industry
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Some companies approach Additive Manufacturing as a drop-in replacement for conventional manufacturing technologies. This approach, however, does not take into account the unique possibilities that additive processes offer and can result in parts that are not commercially viable due to cost. By designing parts specifically for AM, companies can reduce costs and improve efficiency while taking advantage of the possibilities offered by the technology. In this report, Olaf Diegel and Terry Wohlers look at the impact of good AM part design on machine operating costs [First published in Metal AM Vol. 4 No. 1, Spring 2018]
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Additive Manufacturing continues to gain a reputation as a key technology that will have a major impact on all aspects of mechanical engineering. Under the guidance of Major Ryan O’Hara, the United States Air Force’s (USAF) Air Force Institute of Technology (AFIT), based in Dayton, Ohio, has expanded its AM-focused education and R&D capabilities with the purchase of a Laser Powder Bed Fusion system from Germany’s Concept Laser. In the following article, AFIT’s Benjamin Doane and colleagues highlight work done at the institute to develop AM test bed components to support a high temperature testing programme [First published in Metal AM Vol. 4 No. 1, Spring 2018]
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