Processing

Simufact Additive: Accelerating the metal Binder Jetting workflow with sintering simulation

The ability to ‘design out’ distortion during sintering is seen as key to enabling the faster commercialisation of metal Binder Jetting (BJT). The Simufact Additive software platform, now on the third release of its BJT sintering module, is able to accurately simulate the sintering process, predicting shrinkage, slumping and friction-related distortion, either with or without ‘live’ and ‘ceramic’ setters, resulting in a downloadable ‘compensated’ component geometry to be fed directly to the AM machine. In this article, Jeff Robertson explores through case studies how The ExOne Company has been using the software in its AM adoption and R&D centres to optimise customer parts for sintering. [First published in Metal AM Vol. 6 No. 3, Autumn 2021] ... Read more »

How X-ray Computed Tomography is helping an AM service bureau to improve predictive-model based qualification

As metal Additive Manufacturing continues to grow as a technology for the production of critical end-use parts for the most demanding of applications, X-ray Computed Tomography (CT) remains an unrivalled non-destructive testing tool. In this article, Yxlon’s Nathan Serafino and Dirk Steiner report on how Materials Resources LLC, an additive metals research and manufacturing company, defence contractor, and ‘fast factory’, is going a step further, using the technology to improve predictive-model based qualification processes as well as to calibrate in-process monitoring. [First published in Metal AM Vol. 6 No. 3, Autumn 2021] ... Read more »

Separating metal AM parts from the build plate – an underestimated challenge

Within the Additive Manufacturing workflow, it is easy to underestimate the challenge of removing parts from a build plate. As GF Machining Solutions’ Dogan Basic explains, in Laser Beam Powder Bed Fusion (PBF-LB) the wrong choice of equipment can lead to higher costs, longer build times and even part breakages. In response to this challenge, the company developed a solution designed specifically for PBF-LB build plate removal: the AgieCharmilles CUT AM 500. Here, Basic introduces the features and benefits that the CUT AM 500 brings to the industry. [First published in Metal AM Vol. 6 No. 3, Autumn 2021] ... Read more »

Reducing residual stress with 500°C build chamber preheating for ‘first time right’ PBF-LB

According to Germany’s Trumpf GmbH + Co. KG, preheating the substrate plate in Laser Beam Powder Bed Fusion (PBF-LB) to 500°C brings significant advantages in serial production: complex parts are more likely to be built successfully on the first try, design freedom increases, there is little residual stress and no cracks – and, for the first time, high-carbon alloy parts can be built reliably, without cracks, to a density comparable with their conventionally produced counterparts. Here, the company shares the results of tests demonstrating the advantages of 500°C preheating, and introduces the technology making it possible for manufacturers to integrate this step into their PBF workflow, and reap the benefits. [First published in Metal AM Vol. 6 No. 3, Autumn 2021] ... Read more »

Taking the holistic view: Defining the state-of-the-art in the evolving PBF-LB machine marketplace

In a rapidly evolving Additive Manufacturing landscape, choosing a machine for the production of parts by Laser Beam Powder Bed Fusion (PBF-LB) is now about far more than a cost per part calculation. In this article, Sebastian Becker, EOS GmbH, considers how a host of additional factors now need to be considered when exploring the AM machine marketplace, from the specifics of a machine’s operation to software, IP protection and beyond. [First published in Metal AM Vol. 7 No. 2, Summer 2021] ... Read more »

Metal AM magazine Summer 2022

Forging a process for mass customisation via metal Additive Manufacturing

Metal Additive Manufacturing technologies offer the potential for true mass customisation, but in order to leverage this opportunity, new, complex workflows and business models have to be implemented. In this article, Siemens Digital Industries Software’s Ashley Eckhoff considers the challenges when addressing the topic, from the addition of further complexity, to an already challenging Additive Manufacturing workflow, to traceability and regulation. By adapting the AM process to meet these needs, companies can reap the benefits of new markets uniquely suited to this technology. [First published in Metal AM Vol. 7 No. 2, Summer 2021] ... Read more »

Metal AM magazine Summer 2022

Optimised thermal management in semiconductor fabrication using AI-enabled generative design and Additive Manufacturing

An unexpected consequence of the COVID-19 pandemic has been its impact on the multibillion dollar semiconductor microchip market: at the very same moment as demand for consumer electronics skyrocketed due to global lockdowns, the supply of semiconductors was bottlenecked by production disruptions. Now, supply chain shortages threaten the production volume of the industries dependent on these parts. Scott Green and Niels Holmstock, 3D Systems, and Lieven Vervecken and Gert-Jan Paulus, Diabatix, explore how metal AM can be used to increase efficiency in semiconductor fabrication and boost the speed at which these vital components can be produced. [First published in Metal AM Vol. 7 No. 2, Summer 2021] ... Read more »

Metal AM magazine Summer 2022

The need for speed, and how the right powder can reduce AM part production costs by 50%

If metal Additive Manufacturing is to compete with casting and other mass-production technologies, costs need to be reduced by a factor of ten. Optimising metal powder characteristics can get the industry halfway there, while anticipated improvements in equipment and processes will do the rest. Here, Equispheres’ Doug Brouse and Dr Martin Conlon discuss how the use of advanced aluminium powders can improve the build rate for Laser Beam Powder Bed Fusion (PBF-LB) by two to four times, as well as offering significant advantages for Binder Jetting (BJT) production. [First published in Metal AM Vol. 7 No. 1, Spring 2021] ... Read more »

Metal AM magazine Summer 2022

Additive Manufacturing of aluminium parts by Directed Energy Deposition: Possibilities and challenges

SAMOA, a European Union funded EIT RawMaterials project on ‘Sustainable Aluminium Additive Manufacturing for High Performance Applications’, investigated the processing of aluminium powders by Directed Energy Deposition. In this report, Himani Naesstroem, Joerg Volpp, Stefan Polenz, and Frank Brueckner review the effects of processing parameters and feedstock material age, as well as presenting an industrial case study. [First published in Metal AM Vol. 7 No. 1, Spring 2021] ... Read more »

Metal AM magazine Summer 2022

Euro PM2020 technical review: Advances in process control for metal Binder Jetting (BJT)

Within the programme of the well-received Euro PM2020 Virtual Congress, held October 5–7, 2020, and organised by the European Powder Metallurgy Association (EPMA), a technical session was held on process control in metal Binder Jetting. In this article, Dr David Whittaker provides a summary of two of the papers presented, which look at applying the Master Sintering Curve for 316L parts, and process parameter optimisation for 17-4 PH parts. [First published in Metal AM Vol. 7 No. 1, Spring 2021] ... Read more »

Metal AM magazine Summer 2022

In the latest issue of Metal AM magazine

Download PDF
 

Extensive AM industry news coverage, as well as the following exclusive deep-dive articles:

  • Transforming access to medical implants with PrinterPrezz
  • Lessons from 2021’s Olympic bike crash
  • Xerox liquid metal AM
  • Additive Manufacturing for oil, gas and maritime
  • Multi-material metal parts by Powder Bed Fusion
  • Findings from Wohlers Report 2022
  • The challenge of grain size: X-ray powder diffraction analysis of parts made by metal AM

The world of metal AM to your inbox

Don't miss any new issue of Metal AM magazine, and get the latest industry news. Sign up to our twice weekly newsletter.

Sign up

News from the industry…

    News from the industry…

    Discover our magazine archive…

    The free to access Metal Additive Manufacturing magazine archive offers unparalleled insight into the world of metal Additive Manufacturing from a commercial and technological perspective through:

    • Reports on visits to leading metal AM part manufacturers and industry suppliers
    • Articles on technology and application trends
    • Information on materials developments
    • Reviews of key technical presentations from the international conference circuit
    • International industry news

    All past issues are available to download as free PDFs or view in your browser.

    Browse the archive

    qweqw

    Looking for AM machines, metal powders or part manufacturing services?

    Discover suppliers of these and more in our comprehensive advertisers’ index and buyer’s guide, available in the back of Metal AM magazine.

    • AM machines
    • Process monitoring & calibration
    • Heat treatment & sintering
    • HIP systems & services
    • Pre- & post-processing technology
    • Powders, powder production and analysis
    • Part manufacturers
    • Consulting, training & market data
    Download PDF