Metal 3D printing solutions provider Sciaky, Inc., well known for its extremely popular Electron Beam Additive Manufacturing (EBAM) process, just announced that it has entered into a research and development initiative with metallurgist expert Aubert & Duval – a subsidiary of the Eramet group’s Alloys division – and Airbus, one of its previous 3D printing partners. The ambitious initiative, also called the Metallic Advanced Materials for Aeronautics (MAMA) project, is being driven by the Saint Exupéry Institute for Research in Technology (IRT), and the academic partner for the project is the Production Engineering laboratory of the National School of Engineering in Tarbes, France.
“Sciaky is proud to work with the Saint Exupéry IRT, Aubert & Duval and Airbus on this exciting project. Industrial metal additive manufacturing technology continues to break new ground every day, and Sciaky is committed to keeping EBAM at the forefront of this movement,” said Scott Phillips, the President and CEO of Sciaky, Inc., a subsidiary of Phillips Service Industries, Inc. (PSI).
In terms of work envelope, Sciaky’s exclusive EBAM technology is probably the most widely scalable metal AM solution in the industry. It’s the only industrial metal 3D printing process that has approved applications for air, land, sea, and space, with gross deposition rates up to 11.34 kg of metal an hour, and is able to manufacture parts from 203 mm to 5.79 meters in length. Rather than just melting the outer layer of the metal powder, the EBAM process completely liquefies the metal wire feed.
The fast, cost-effective EBAM process offers a wide range of material options, including titanium, for large-scale metal applications, and uses its adaptive IRISS (Interlayer Real-time Imaging and Sensing System) to combine quality and control, as the patented system can sense, and digitally self-adjust, metal deposition with repeatability and precision. It is mainly due to the IRISS system that the Chicago-based company’s EBAM 3D printing process is so good at delivering, as the company puts it, “consistent part geometry, mechanical properties, microstructure, and metal chemistry, from the first part to the last.”
The goal of its combined MAMA project with Airbus and Aubert & Duval is to combine traditional metallurgy (high-power closed die forging) with new wirefed metal 3D printing techniques, such as Sciaky’s EBAM process, in order to come up with new processes for manufacturing titanium alloys that can be used to make aircraft parts. Based on the caliber of its partners, Sciaky made a good decision in joining the R&D initiative – Airbus is a 3D printing pioneer in the aerospace industry, and Aubert & Duval creates and develops advanced metallurgical solutions for projects in demanding industries, such as nuclear, medical, energy, defense, and aeronautics.
The project’s first phase has global funding in the amount of €4.2 million. 50% of this funding is supported by the French State as part of its “Investing in the Future” program (Programme Investissement d’Avenir, or PIA), while the other half is funded by industrial partners of the initiative.
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Ruselectronics, a Russian holding corporation and a subsidiary of state-owned Rostec, is developing an electron beam metal 3D printer for aerospace applications. The research and development work will be carried out by Toriy Scientific Production Association (НПП Торий). Toriy is a subsidiary of Ruselectronics and specializes in electron beam welding, microwave tubes, and communication systems. Dmitry Trofimov from Toriy, […]
We’re starting off today’s 3D Printing News Briefs with a product launch announcement – 3YOURMIND launched the full version of its Agile MES software software this week at AMUG 2019. Moving on, Sintratec will present its latest SLS 3D printer at RAPID + TCT next month in Detroit, Tiamet3D has joined Ultimaker’s material alliance program, and Sciaky entered into an agreement with KTM Consultants. Xometry just announced some important certifications, and nScrypt is 3D printing titanium parts. Moving on to the world of art and theatre, the Zurich Opera House is 3D printing props, and artist Andrea Salvatori worked with WASP to create a 3D printed art collection.
3YOURMIND Launched Agile Manufacturing Execution System (MES) Software
After spending five years providing order management systems to scale for some of the industry’s AM leaders, 3YOURMIND has finally moved its software solutions to a production environment with the launch of its Agile Manufacturing Execution System (MES) earlier this week at AMUG 2019. The software uses smart part prioritization, rapid scheduling, order tracking, and custom AM workflow creation to improve machine utilization and make production more efficient, and an Early Access Program (EAP) allowed the company to receive direct feedback on its Agile MES software from representatives at companies like EOS and Voestalpine. The next step will be working to finalize machine connectivity.
“For Agile Manufacturing, the Agile MES will need to both GET and PUSH data from all major AM machines and post-processing systems. We are already integrating the data from several vendors into our software and expect to support all major machines,” explained 3YOURMIND’s CEO Stephan Kühr. “Receiving and processing machine data allows us to provide the documentation that is needed for quality assurance and to increase the repeatability of additive manufacturing. Pushing data directly to machines will be the key to automating production.”
Sintratec Showcasing New SLS 3D Printer at RAPID + TCT
A few months ago, Swiss SLS 3D printer manufacturer Sintratec introduced its scalable, modular Sintratec S2. Now, the company will be presenting the printer in the US for the first time next month at RAPID + TCT in Detroit, which will also be Sintratec’s first time attending the massive event. What makes the Sintratec S2 stand out is its closed-loop workflow, as the complete system covers every process with its three modules: the Laser Sintering Station (LSS), the Material Core Unit (MCU), and the Material Handling Station (MHS). The 3D printer offers quick material changes, a 4K camera for print monitoring, improved ergonomics, and effective heat distribution through its cylindrical printing area and ring lamps.
“The Sintratec S2 will boost the design of applications and gives the user the opportunity to set foot in small series production as well. And that for an unusually attractive price-performance ratio,” said Sintratec CEO Dominik Solenicki.
“With the Sintratec S2 solution we will be opening new opportunities for companies of any size.”
The price for the Sintratec S2 starts at $39,900, and you can see it for yourself at Sintratec’s booth 1753 at RAPID + TCT from May 20-23.
Tiamet 3D Joins Ultimaker’s Material Alliance Program
Last year, Dutch 3D printing specialist Tiamet 3D, founded in late 2014, worked with Finland-based Carbodeon to develop the first nanodiamond-enhanced 3D printing filaments, which went on the market in September. Now the company has joined Ultimaker as a partner in its Material Alliance Program. Together, the two will offer end-users simple one click downloads of Tiamet’s ULTRA Diamond material profile, which is now available on Ultimaker’s Cura software. This collaboration is formally backed by Tiamet’s manufacturing partner Mitsubishi Chemical Performance Polymers (MCPP Netherlands).
Reid Larson, the Director and Co-Founder of Tiamet 3D, told us about some of the highlighted specs of its ULTRA Diamond material, including no additional nozzle wear, 6300 mpa stiffness, low moisture absorption and friction, improved thermal conductivity, and twice “the temperature resistance of normal PLA, Annealed goes to 125C HDT.” You can purchase one kg of ULTRA Diamond filament for €59.
Sciaky Increasing Sales Efforts Through New Agreement
In an effort to increase the sales efforts of its Electron Beam Additive Manufacturing (EBAM) solutions in Australia, the Middle East, and New Zealand, Sciaky, Inc. has entered into an agreement with KTM Consultants, founded by metallurgist Trent Mackenzie in 2015. In terms of sheer work envelope, Sciaky’s massive EBAM systems are the industry’s most widely scalable metal 3D printing solution, able to produce parts ranging from 8 inches to 19 feet at gross deposition rates of up to 25 lbs of metal an hour. Additionally, its Interlayer Real-time Imaging and Sensing System (IRISS) is the metal 3D printing market’s only real-time adaptive control system capable of sensing and digitally self-adjusting its deposition.
“I was immediately drawn to Sciaky’s EBAM technology because of its unique and robust capabilities. Industrial manufacturers of large metal parts need to explore the significant advantages that technologies like EBAM offer. It is truly a game-changer,” said Mackenzie.
Xometry Announces New Industry Certifications
Digital manufacturing marketplace Xometry announced that it has just received ISO 9001:2015 and AS9100D certifications – some of the most rigorous, widely-recognized quality management designations in the industry. ISO 9001 helps organizations meet the needs and expectations of their customers in terms of quality management, while AS9100 meets customer demands in the exacting aerospace and defense industries. The company went through a major audit as part of the process, and its achievement definitely reflects how committed Xometry is to providing quality.
“We are thrilled to receive this designation. Our team members have a passion for providing great customer service while following the disciplines that give our customers peace of mind regarding on-time delivery, quality, and continuous improvement. It is yet another step towards achieving industry “best in class” status and being able to meet the expanded needs of our customers,” stated Xometry COO Peter Goguen.
nScrypt Develops Proprietary Method for 3D Printing Titanium
nScrypt 3D printed titanium gear, dogbone, and block
Florida manufacturer nScrypt, which develops high-precision Micro-Dispensing and Direct Digital Manufacturing equipment and solutions, is now focusing on repeatable 3D printing of metals for the medical, defense, and aerospace industries. The company has created a proprietary method for 3D printing titanium parts, which tests have shown display densities comparable to wrought parts. This method could easily work with other metals as well, such as copper, Inconel, and stainless steel, and nScrypt’s Factory in a Tool (FiT) systems can finish or polish areas with high tolerance features using its integrated precision nMill milling head. nScrypt’s Brandon Dickerson told us that the company expects to release more details on this later in 2019.
“The parts were printed with our SmartPump Micro-Dispensing tool head, which runs on any of our systems,” Dickerson told 3DPrint.com. “The parts shown in the photos were printed on our DDM (Direct Digital Manufacturing) system, also known as our Factory in a Tool (FiT) system, which can run 5 tool heads at the same time, including our Micro-Dispensing, Material Extrusion, micro-milling, and pick-and-place tool heads. The parts were sintered after the build and the current densities are in the high 90% range. We expect our system to appeal to customers who want to do Direct Digital Manufacturing and need strong metal parts, but cannot build them with a powder bed system (for example, if the geometry would trap powder inside) or prefer not to use a powder bed system (for example, if they want a cleaner system).”
Zurich Opera House 3D Printing Props with German RepRap
Finished tutu for “The Nutcracker”, which was produced with the help of the x400 3D printer
Switzerland’s largest cultural institution, the Zurich Opera House, puts on over 300 performances a year, but the behind-the-scenes magic happens in the studios and workshops, where the props and costumes are made. The opera house uses the x400 3D printer from German RepRap, with assistance from Swiss reseller KVT- Fastening, to support its creative work by fabricating props and molds. This affords the institution more creativity and flexibility, as they can design objects to their exacting needs in 3D modeling programs, which also helps save on time and money. The opera house currently uses PLA, which is easy to handle, offers a variety of colors, and is flame retardant – very important in a theatrical setting.
“Often, the wishes and ideas of costume and stage designers are very diverse and sometimes extraordinary. It often happens that props are not available in the way designers have it in their minds. This is where the 3D printer is perfect for,” said Andreas Gatzka, director of theater sculpture at the Zurich Opera House.
“There are a lot of great benefits. Special wishes of stage and costume designers can be realized quickly as well as a short-term change of the objects, for example larger, smaller, longer, shorter, or whatever is needed.”
3D Printed Art Collection
Artist Andrea Salvatori 3D printed the eye-catching pieces for his new collection, titled Ikebana Rock’n’Roll, using the Delta WASP 40100 Clay 3D printer – designed by WASP to be used by ceramic and clay artists. The collection just opened on stage at THE POOL NYC in Milan last week, and will be available to view until May 31st. With these 3D printed vases, Salvatori wanted to use “a miscellany of ceramic insertions” to mess with the high quality shapes 3D printing can achieve by adding asymmetry.
“The process of depositing the material and setting the spheres is a central theme in the Ikebana Rock’n’Roll collection, to the point of convincing Salvatori to name the works “Composition 40100”, as if they originated from a musical dialogue of the most varied tones. The artist upsets the algorithm reiterated slavishly by the machine with imperfect musical accents, the result from time to time of spontaneous actions and reasoned processes,” WASP wrote in a blog post.
“The ikebanes, proposed by Andrea Salvatori in the exhibition, transcend the experimental limits of an abstract investigation, representing a concrete territory in which 3D printing and ceramic art co-exist synergistically. The Master challenges the confrontation with the public, becoming also in this sector, precursor of a new genre in which WASP feels itself fully represented.”
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Fabio Sant´Ana is from Brazil a country we associate with beaches, football, and carnivals. Yet, the verdant green Carnival-land has much more potential than just being a fun place. Brazil produces aircraft, has growing international companies, a large auto industry, and a growing medical industry. Meanwhile, it has also had some tough years behind in politically and economically. For years Fabio has been trying to bring metal 3D printing and industrial 3D printing solutions to Brazil with Farcco Tecnologia. In this difficult economic environment, he’s been trying to get companies to industrialize metal 3D printing, trying to get companies to start making titanium medical devices in Brazil and doing what he can to 3D print Brazil.
Fabio started with a Precision Mechanics Degree and since then has worked in precision machining for over 25 years. He is a specialist in metal 3D printing and has a deep understanding of EBM in particular. He’s worked with a number of blue-chip companies in Brazil and has helped them to go from knowing next to nothing to industrializing 3D printing for manufacturing. Fabio is a part of the ASTM F42 Additive Manufacturing, ISO TC26, ABNT CEE-261 Manufatura Aditiva and ABNT CB-26 Odonto-Médico-Hospitalar standardization efforts and an expert in Design For Additive Manufacturing.
What is Farcco Tecnologia?
Farcco Tecnologia is a company devoted to introducing Additive Manufacturing technologies to the Brazilian Industries, it is specialized in real metal additive production technology, and is really reaching out to every possible specialization in AM . The main focus is expanding the knowledge of Brazilian market. Farcco researches and finds the most important technologies thru shows, conferences , training and suppliers to make Brazilian Industries to reach the same level of capability and expertise found overseas .
What is the 3D printing market in Brazil like?
The Brazilian Additive Manufacturing market is developing in slower pace, the last 8 years did hold Brazil back in terms of R&D. In a not growing, or more in a depressed economy, is hard for companies to justify investment in new, and technology advanced, manufacturing capacities. Starting in 2018 with the new government , companies started to forecast economic growth for the next years and this made the industrial environment reach out to us, for 3D printing, to revamp their production resources. In Brazil the medical market is the first adopter in additive and had the first equipment, this is being used for manufacturing titanium implants. During 2017 and 2018, more companies are beginning to understand the real advances of the technology and its benefits in quality, product development and cost saving features. Aerospace started to evaluate AM during 2018 and the first metal machine should be working in Q1 2019 . Most machines installed before this new boom time are in Universities and Research Institutes.
We see very few Brazillian 3D printing startups? How could this be improved?
Brazil has a very limited investment capability, this is what holds us back, the startup environment is not well supported by banks and startups normally only rely on Private Equity and Angel Investments. AM is very capital intensive in case of equipment for startups and this makes it difficult to do.
Is metal 3D Printing increasing in Brazil?
Yes , companies have started to realize the beauty of the technology. Many companies are looking for information in that area,, and some have already started to R&D using smaller or cheaper machines to be able to develop and go for real production machines in a shorter time.
What advice would you give me if I’m an OEM or a materials company wanting to do business in Brazil?
Call me ! … Joking … anyway , Brazil is different in many ways. Lack of infrastructure and investment as well as a difficult tax structure create many entrance barriers for foreign companies , To find a very knowledgeable local partner is something that can keep the company on right track with the right information one can jump many steps and problems. To invest in training of locals to support the “pre” and “after” sales is also a good advice . Brazilian Industry is used to local support and short service time.
What opportunities do you see for Brazil in 3D printing?
“Most of the actual opportunities are in medical , so beside of metals, medical polymers and bio-printing can be better explored . We are growing also in Oil & Gas and Renewable Energy, both have good growth in Brazil , Additive has great features for these areas.”
You’ve been a long time EBM expert what do you see as some of the advantages compared to other metal technologies?
The EBM process has some nice specific characteristics that benefit reactive materials such as titanium, it can supply more energy and generates up to 70 simultaneous melt pools. This is what lets you grow fast compared with other process that have 1 , 2 or 4 melt pools. The way electron beam hits the powder is different than laser, that is basic light and has its particular ways of propagation reflection etc. In EBM energy loss is much lower that also benefits the process. EBM is a less precise in terms of geometry, but can stack parts filling the build chamber, another benefit in terms of production quantities and gives one more balanced building cycles. Each process has its advantages. Laser has a very good precision and also better finished surface, this can work well with steel and forms a less compact build cake what makes cleaning the powder easier in cases of something such as conformal cooling . In Additive Manufacturing each process has its right business case. Every technology has its niches and must be well understood to give you the best results.
The Q10+ and Q20+ have reached a very stable processing and performance. The Spectra is a big chamber focused on TiAl and bigger quantites. The products are all reaching a very mature state.
You’re not active in binder jetting metals, how come?
Let me tell you how I started in Additive, I’ve been a machining guy since 1991 when I left the Precision Mechanics Technical High School. I’ve been supplying the market with CNC machining equipment since 1992 had to develop skills in 3D manufacturing since that time , from complex mass production processes to really difficult 5 axis applications all in my range. In 2013 a medical implants company R&D manager and friend came to me with a very crazy part he found in Europe and asked me how to make that thing. I told him ” I dont know , yet “. My Additive journey started in that day of 2013, after almost 6 years researching, learning, teaching and going all over the world to be able to implement additive equipment and technologies, I know that each technology has its case, binder jetting cases will appear, no doubt. But, for now, I don’t know yet.
You do work with Sciaky EBAM?
EBM has very good performance in medical and Aerospace, most of the companies in those segments are paying attention to EBM. For larger structural parts Sciaky makes an EBAM based machine that melts wire forming near net shapes for posterior machining, its a processe that speeds up the production of this components a lot , it has potential to short by months the development and manufacturing of large titanium and other metals parts. In Brazil, we don’t have any Sciacky EBAM yet.
I see a lot of potential in using it to rejuvenate molds and blisks, but this is not used a lot?
I really agree with you, but the economics are against it right now, To use a DED head over a mold inside a CNC machining center makes more than sense. However, DED heads or Hybrid machines need economically to fight against a regular machining center that receives a mold filled by a very experienced welder. When you put that in your financial spreadsheet you have the answer why this is not being more used. The final shape and precision will come from the machining anyway, and you already have the welder in your payroll, so …
What do you think the potential of 3D printing?
“AM is a marvelous tech, I think we are only scratching the surface of the technology and the new designs made by biomimetcs and topology and generative systems will give us products we cannot even imagine now… so the sky is the limit.?
In order to hold up under difficult launch conditions and decade-long missions in the zero gravity conditions of outer space, satellite fuel tanks need to be both lightweight and strong. Titanium is an obvious choice of material, but it can take over a year to acquire 4-foot-diameter, 4-inch-thick titanium forgings, which also increases the overall cost of the tank. Additionally, if traditional manufacturing methods are used to fabricate these forgings, over 80% of the material is wasted.
This infographic shows the scale of the 3D printed domes, their placement on the tank, and overall location within an LM 2100 satellite.
That’s why Lockheed Martin chose to employ 3D printing to create a record-setting, 46-inch-diameter titanium dome for its satellite fuel tanks.
“Our largest 3-D printed parts to date show we’re committed to a future where we produce satellites twice as fast and at half the cost. And we’re pushing forward for even better results,” Rick Ambrose, the Executive Vice President of Lockheed Martin Space, explained. “For example, we shaved off 87 percent of the schedule to build the domes, reducing the total delivery timeline from two years to three months.”
The new fuel tank for Lockheed Martin’s largest satellites have 3D printed domes integrated into the body to cap them off.
The tank is made up of a traditionally manufactured, variable-length titanium cylinder, which is capped by two 3D printed domes; these three pieces are then welded together to make up the final product. Technicians at Lockheed Martin’s Denver facility fabricate the domes using Electron Beam Additive Manufacturing (EBAM) technology on a large 3D printer.
By 3D printing the domes, there is no longer any material waste, and the titanium is available to use with no wait time, which lowers the delivery time of the satellite tank from two years to just three months. This in turn helps the company cut its satellite schedule and costs by 50%.
“We self-funded this design and qualification effort as an investment in helping our customers move faster and save costs. These tanks are part of a total transformation in the way we design and deliver space technology,” said Ambrose. “We’re making great strides in automation, virtual reality design and commonality across our satellite product line. Our customers want greater speed and value without sacrificing capability in orbit, and we’re answering the call.”
These 3D printed tank domes are far bigger in size for the company’s qualified 3D printing materials – previously, its largest part was an electronics enclosure for the Advanced Extremely High Frequency satellite program that was only the size of a toaster. That makes these domes, which are large enough to hold nearly 75 gallons of liquid, a pretty big leap.
A Lockheed Martin engineer inspects one of the 3D printed dome prototypes at the company’s space facility in Denver.
The final rounds of quality testing for the satellite fuel tank and its 3D printed domes were completed earlier this month, which finally ends a multi-year development program with the goal of successfully creating giant, high-pressure tanks to carry fuel on satellites. Lockheed Martin technicians and engineers spared nothing on their quest to ensure that the tanks would meet, and even exceed, the reliability and performance required by NASA, as even the tiniest of flaws or leaks could spell disaster for a satellite’s operations.
The structure of the vessel was “rigorously evaluated,” according to a release, and the company’s techs ran it through an entire suite of tests in order to demonstrate its repeatability and high tolerances. Lockheed Martin is now offering the large satellite fuel tank, complete with its two 3D printed domes, as one of the standard product options for its 2100 satellite buses.
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In terms of work envelope, Sciaky’s exclusive EBAM technology is probably the most widely scalable metal AM solution in the industry. It’s the only industrial metal 3D printing process that has approved applications for air, land, sea, and space, with gross deposition rates up to 11.34 kg of metal an hour, and is able to manufacture parts from 203 mm to 5.79 meters in length. Rather than just melting the outer layer of the metal powder, the EBAM process completely liquefies the metal wire feed.
