X-ray Computed Tomography (CT), also widely known as MicroCT, is a proven method for not only checking the structural integrity of additively manufactured (AM) parts – for example for unwanted porosity – but also for checking a build’s dimensional accuracy. The main advantage of the technique is of course the non-destructive nature of the assessment; however, there are also many misunderstandings about the capabilities and complexity of the technology. Prof Anton du Plessis and Dr Jess M Waller review the application of CT testing in relation to metal AM and highlight the advantages of a move towards standardised test methods [First published in Metal AM Vol. 4 No. 4, Winter 2018]
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From November 13-16, 2018, the Additive Manufacturing world congregated in Frankfurt, Germany, to attend the year’s final and arguably most significant international exhibition on the technology. Occupying more than 37,000 m2 of floor space, Formnext 2018 attracted nearly 27,000 visitors – an increase of more than 25% on the previous year – and over 600 global exhibitors. In this report, Metal AM’s Emily-Jo Hopson covers some of the news and developments out of Formnext, and looks at how they reflect an industry turning its focus toward productivity and efficiency for true industrialisation [First published in Metal AM Vol. 4 No. 4, Winter 2018]
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Organised by the U.S. Commercial Service in Dusseldorf, Germany, the Additive Manufacturing/3D Printing Standards Forum took place on November 14, 2018, in Frankfurt, Germany, at the Formnext trade fair. As Dr Georg Schlieper reports, the event brought together leading experts from industry, research institutions, standards developing organisations, professional societies and government to address key themes focused on standards development in AM technologies. This included progress on international standards development for AM and how the use of these standards can help the industry achieve its potential [First published in Metal AM Vol. 4 No. 4, Winter 2018]
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Anyone who starts out on their own evaluation of the opportunities presented by metal Additive Manufacturing will soon stumble across the phrase ‘build failure’. Whilst there can be many causes for a failed build, which of course comes at a significant cost in terms of both material wastage and machine time, residual stress is often at the top of the list. As Olaf Diegel and Terry Wohlers explain, residual stress can be both anticipated and managed though a combination of basic design rules, process settings and post-build heat treatment [First published in Metal AM Vol. 4 No. 4, Winter 2018]
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As one of the world’s largest industrial companies, Siemens has experienced first hand the process of taking metal AM from the R&D laboratory to the series production of critical components for its power generation business. Today, it is supporting the global industrialisation of the technology through its Siemens NX Additive Manufacturing software. In the following report the company’s Aaron Frankel and Ashley Eckhoff explain their belief that, whilst the potential of AM is massive, digitalisation will play a critical role in enabling its transition from a prototyping tool to a serial production technology [First published in Metal AM Vol. 4 No. 3, Autumn 2018]
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With the launch of HP’s new Metal Jet system, Binder Jetting looks like the technology that will help move metal Additive Manufacturing into the realms of mainstream high-volume manufacturing. GKN Powder Metallurgy is set to be the first global parts manufacturer to move into mass production with this technology and, in the following report, the company outlines the evolution of its AM operations to-date and its expectations for the future [First published in Metal AM Vol. 4 No. 3, Autumn 2018]
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In July 2018, Metal Additive Manufacturing magazine’s Emily-Jo Hopson attended the company’s exclusive EOS Technology Days for an advance preview of its new metal Additive Manufacturing system, the EOS M 300, and a look at its vision for AM and the technology’s place in the digital factory of the future. Held at the company’s attractive rural headquarters in Krailling, Germany, the event offered attendees insight into areas that are key to EOS’s current development strategy [First published in Metal AM Vol. 4 No. 3, Autumn 2018]
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What’s happening in metal Additive Manufacturing in China? Quite a lot it seems; however, the extent and nature of this activity, and what can be expected from Chinese systems manufacturers in the coming years, can be unclear to Western observers. In the following report, Joseph Kowen offers a brief look into the current state of the metal AM industry in China. As well as presenting an overview of machine-related activity in this fast growing part of the world, he considers to what extent we can expect to see an increased presence of Chinese suppliers in western countries [First published in Metal AM Vol. 4 No. 3, Autumn 2018]
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In recent years there has been a surge in interest in the use of Binder Jetting and Fused Deposition Modelling for the production of low to medium volumes of metal additively manufactured parts. In the following report, Maximilian Munsch, Matthias Schmidt-Lehr and Eric Wycisk of Ampower GmbH & Co KG, Hamburg, Germany, review how the success of Metal Injection Moulding has enabled these technological innovations. They also compare some of key properties and costs to enable designers to better understand the readiness of these technologies for commercial production [First published in Metal AM Vol. 4 No. 3, Autumn 2018]
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Over the past few years, metal Additive Manufacturing has received a lot of attention, and with good reason: the technology has the potential to radically alter the design and production of components and products in many industries. Yet in spite of the excitement that surrounds AM, the prospect of wider industrial adoption continues to face significant challenges. Ansys Inc’s Dave Conover explains how simulation, traditionally the domain of product design instead of manufacturing, has swiftly gained recognition as a key technology which can be used to ease the transition from conventional to Additive Manufacturing [First published in Metal AM Vol. 4 No. 3, Autumn 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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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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