Wayland Additive’s NeuBeam process to open up further industrial applications

April 28, 2020

An additively manufactured impeller part produced using the NeuBeam process with no post-processing (Courtesy Wayland Additive Limited)

Wayland Additive, Huddersfield, UK, has announced the development of a new metal Additive Manufacturing method it calls the NeuBeam® process. Said to be an entirely new Powder Bed Fusion (PBF) process, it is claimed that NeuBeam offers the best of both laser and electron beam PBF systems, opening up Additive Manufacturing to a wider range of industrial applications.

Will Richardson, CEO of Wayland, explained that the new technique is an eBeam PBF process that effectively neutralises the charge accumulation generated by the electron beam. This offers greater flexibility than L-PBF while overcoming any stability issues associated with eBeam PBF. In addition, this means that the NeuBeam process enables metallurgical requirements to be tailored to application requirements rather than to maintain the print process within the narrow bounds permitted by the process.

“At Wayland Additive, we have been working on the development of an entirely new PBF process for metal Additive Manufacturing that minimises the existing limitations that current users have to work around. When considering the existing two PBF technologies, NeuBeam offers a new way, a third way,” stated Richardson.

Although EBM and NeuBeam are both PBF processes, using an electron beam as the heat source to melt the metal powder, it is stated that EBM and NeuBeam are fundamentally different. Unlike the traditional eBeam PBF process, the charging issues that can make EBM unstable have been fully neutralised with NeuBeam using core physics principles developed in the demanding semi-conductor industry. Moreover, NeuBeam is a hot part process rather than a hot bed process. This efficiently creates parts that are free of residual stresses because the high temperatures are only applied to the part and not the bed, ensuring free-flowing powder post-build (no sinter cake) and stress-free parts with reduced energy consumption.

In process view of the NeuBeam process, producing impeller part (Courtesy Wayland Additive Limited)

Furthermore, the process is reported to overcome many of the limitations for additively manufacturing large components – no residual thermal stresses, no gas cross-flow, and a much simplified powder removal process than existing eBeam systems.

The NeuBeam process is capable of producing fully dense parts in a wide range of materials, many of which are not compatible with traditional EBM or L-PBF processes such as refractory metals and highly reflective alloys. 

NeuBeam also offers built-in real-time in-process monitoring, allowing for rapid material development or tuning of microstructures by adapting the solidification during manufacture. With NeuBeam the process temperature is not constrained by sintering the powder bed, allowing the process temperature to be optimised to the material microstructure and/or the application.

The level of in-process monitoring is achieved through a combination of advanced technologies, including structured light scanning, electron imaging and high speed infra-red cameras. Each of these different monitoring approaches are calibrated to the same reference points in the machine, with managed adjustments, to ensure optimum results and output. Being a true thermal process, everything in the build chamber is able to be monitored, and it is possible to see the true temperature of the whole powder bed in-process as a build takes place. The thermal history of the material being processed can also be seen, as can the topography of the surface so that defects can be detected, and reported, as they occur.

www.waylandadditive.com

About Metal Additive Manufacturing magazine

Metal AM magazine, published quarterly in digital and print formats, is read by a rapidly expanding international audience.

Our audience includes component manufacturers, end-users, materials and equipment suppliers, analysts, researchers and more.

In addition to providing extensive industry news coverage, Metal AM magazine is known for exclusive, in-depth articles and technical reports.

Our focus is the entire metal AM process from design to application.

Each issue is available as an easy-to-navigate digital edition and a high-quality print publication.

In the latest issue of Metal AM magazine

Download PDF
 

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

  • Metal powders in Additive Manufacturing: An exploration of sustainable production, usage and recycling
  • Inside Wayland Additive: How innovation in electron beam PBF is opening new markets for AM
  • An end-to-end production case study: Leveraging data-driven machine learning and autonomous process control in AM
  • Consolidation, competition, and the cost of certification: Insight from New York’s AM Strategies 2024
  • Scandium’s impact on the Additive Manufacturing of aluminium alloys
  • AM for medical implants: An analysis of the impact of powder reuse in Powder Bed Fusion

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

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
View online

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

Share via
Copy link
Powered by Social Snap