MTC adds AMCM’s new M 290-2 FLX metal Additive Manufacturing machine
The Manufacturing Technology Centre (MTC), an independent research and technology organisation based in Coventry, UK, has installed an M 290-2 FLX Additive Manufacturing machine from AMCM GmbH, Starnberg, Germany. The metal Laser Beam Powder Bed Fusion (PBF-LB) Additive Manufacturing machine is equipped with two 1200 W variable spot size ‘nLIGHT’ lasers. With full field overlap, both scanners are able to reach all spots on the build plate, ensuring full flexibility with regard to build orientation.
The MTC aims to provide customers with easy and early access to the latest applied technologies and research. It is the National Center of Additive Manufacturing in the UK and a focal point for AM research activities within the country. The team specialises in developing advanced manufacturing processes and technologies to produce complex and large-scale AM components.
AMCM reports it has already shown a significant productivity increase with, for example, IN718 nickel-chromium alloy. Compared to a standard single 400W laser process with 85 µm spot size, a single nLIGHT exposure process is reportedly two times faster in addition to having the same mechanical and surface properties, this is expected to be further improved with an additional laser source.
Gas flow and oxygen levels are often the defining factors in PBF-LB process quality. This is particularly true when speed is increased above a certain threshold or when oxidation-sensitive materials are used. As AMCM specialises in industrial solutions, its systems feature unique long term stable atmosphere control at <50 ppm. MTC will initially use the AMCM M 290-2 FLX for a comprehensive evaluation of pure copper AM, a challenging material when aiming for industrial quality and reliability.
Furthermore, the AMCM machine can heat the build platform up to 500°C. As pre- and post-heat treatment is critical in the processing of certain high-performance aluminium alloys and refractory metals, this enables MTC to evaluate a wide range of high-end applications, such as those in the aerospace and defence industry.
Sina Trik, Sales – AMCM, EMEA, stated, “The UK manufacturing sector is at the forefront of innovation. While the use of materials such as copper offers huge benefits to product designers, manufacturers still face challenges in the Additive Manufacturing process. It’s always amazing to work with MTC – a true thought leader in UK – to expand the field of industrial metal AM.”
As well as exploring new materials, the MTC is also developing ways to increase the speed of AM production and the size of output components. Efficient exposure processes are needed to reduce time and costs. The variable spot sizes of nLIGHT can be switched within 30 ms to build contours and fine structures with maximum precision and infill hatching with accelerated throughput. A larger spot size is a good option for filling bulk material in Additive Manufacturing. This allows users to generate more volume with each pass, significantly reducing the number of hatches and reversal points. Furthermore, the MTC will be investigating novel methods of reducing the need for post processing steps, such as heat treatment, through novel in-situ beam interactions and in-process monitoring.
Equipped with two 1200 W laser sources, the AMCM M 290-2 FLX is a high-power machine. Ruaridh Mitchinson, Technology Manager at the MTC shared, “The laser setup will be identical to what is in future larger AMCM machines such as the AMCM M 8K. We will use our machine to investigate topics such as laser overlap on a smaller scale before going up to using larger systems. This investment demonstrates our continued support to companies by providing open access to assets with advanced AM capabilities that can produce high-performance parts more efficiently and cost-effectively. This way, we can help to increase the technology’s adoption in the UK.”
