Metal Additive Manufacturing

Recently there has been huge growth and interest in the whole area of additive manufacturing or 3D printing. In 3D printing, polymer based parts are made on simple devices using internal movements and controls similar to desk top printers. But instead of ink, the ‘print’ heads extrude a plastic material which is used to grow the 3D part layer by layer. Here we explore the uses and applications of metal additive manufacturing.

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The Arrival of Additive Manufacturing Technologies

Additive manufacturing processes are much in demand right now and have made their way into mainstream news, capturing the imagination of the general public because of the vast potential on offer.

Our infographic below shows how additive manufacturing has revolutionising industry.

Additive Manufacturing: Revolutionizing Industry Infographic from SPI Lasers

Additive Manufacturing: Revolutionizing Industry Infographic

Additive manufacturer processes have been around since the 1980s when Charles Hull invented stereolithography, a type of metal additive layer manufacturing which is still used today.

From the birth of stereolithography, the technology behind what is described as 3D printing was created, generating even greater possibilities. There are now a number of metal additive layer manufacturing companies and the market is competitive and thriving, driving development ever-onwards.

Large scale 3D printing

Large scale 3D printing in progress.

Advantages of additive manufacturing

  • Across many applications additive manufacturing is delivering significant advantages including:
  • Design freedom – enables rapid iterations and flexibility to make design improvements right up to production
  • Ultimate customisation and tailoring – make one-offs as easily as production batches
  • Ability to create complex shape with internal strengthening features
  • Performance from a wide choice of materials to create extremely strong and corrosive resistant parts.
  • Rapid prototyping – see more about rapid prototyping

Using metal additive manufacturing processes doesn’t just deliver advantages, it completely rewrites the possibilities. Shapes and designs that couldn’t previously even be conceived of are now entirely viable, such as parts with scooped out centres. It’s not just the shape which has become possible with additive metal manufacturing, but the lack of compromise. There’s no weakening of the structure and no need to try and weld several parts together, creating vulnerable join areas. Instead, the additive manufacturing metals process can generate a complete shape in its entirety, by carefully layering and bonding materials together to create the desired outcome.

Benefits of 3D metal printing

Across many sectors 3D metal printing is providing an effective alternative to existing processes allowing additive manufacturing companies to create cost-effective production even at low volume as well as shorten lead times, reduce part count and offer many more advantages including:

  • Components can be produced quickly and directly from a CAD model dramatically reducing production time.
  • Eliminate production support processes such as expensive tooling.
  • Lower environmental footprint through the reduction of waste (all non-used powder is re-used). More conventional methods of machine production leave as much as 90% of the original materials on the factory floor, not just wasteful but unnecessarily detrimental to the environment.
  • Deliver savings through improved product design. Metal additive manufacturing can also save on costs by eliminating the need to hold onto expensive inventory parts. With additive manufacturing, materials can simply be “printed” as and when they’re required, saving on not just space but cost too.
  • Additive manufacturing metal is particularly beneficial for products which won’t be made in high volumes and offers a way to create customised shapes and designs far more economically than previously possible.

Changing the face of design

3D metal additive manufacturing has changed the entire design and manufacturing process, creating possibilities which were hitherto unthinkable.

In the past, design models were created based on what could physically be created, with the manufacturing process driving creation and implementation. With the unveiling and expansion of metal printing, the reverse is now true. The primary design is back in the driving seat with concepts and ideas pushing forward, with practicalities over production not a primary concern.

AM also makes it possible for the entirety of the geometry to be developed at the same time, with both the inner parts of a component and the outer shell given equal attention. Creating the piece as a single unit creates strength but with the potential of adding valuable functional elements to the core, some of the results cannot be replicated using any other type of manufacturing.

Types of metal used

It’s possible to use both alloys and pure metals for additive manufacturing with stainless steel; titanium alloys, aluminium and nickel are commonly used. Precious metals can be used too, both for engineering and jewellery purposes, with silver and gold both responding well to AM techniques.

Jewellery produced using metal additive manufacturing methods

Jewellery produced using metal additive manufacturing methods

This great variety of metal and alloys means that it’s possible to select the perfect material for the design, fulfilling criteria such as core strength and also cost. Not all types of metal powder are suitable for AM; the particle size and its spherical geometry can often determine whether it’s appropriate. Once the AM process is complete, the final design can undergo electro polishing to improve the surface finish. This may be required for cosmetic reasons or to deburr the surface, particularly for those items which may be exposed to abrasive substances.

All metals can go through electro polishing if desire, even the small and more fragile components, as there’s no chemical, thermal or mechanical impact created during the process.

The applications of metal additive manufacturing

From its roots in prototypes, metal printing has rapidly become a core technology which has a practical application in a number of different industries. Often described as belonging to a group known as “disruptive technologies” metal printing has the capacity to completely revolutionise the way in which things are made. It’s not currently used in high volume, mass productions, but instead offers the most value where precision engineering is vital or where customisation and flexibility are key.

Fuel nozzles in the aerospace industry are a great example of how this technology is used in practice. The new designs created with the use of metal printing techniques are five times more durable and 25% lighter.

3D printed fuel nozzle

Example of a 3D printed fuel nozzle

It’s these kinds of components where metal printing delivers the greatest benefit, providing the capability to create any geometric shape. Products which will only be made for a short time or in low numbers, where there’s great geometric complexity, those which are extremely small and precise and prototypes and molds all could use metal additive manufacturing rather than conventional means to achieve a far better end result.

Examples of Industrial Use

Although additive manufacturing is seen as a relatively new technology, it has been around for several decades and is already in widespread use across a number of different industries.

Although the concept of 3D printing has only recently captured the public’s imagination and been reported in the media, there’s a number of different industries which have been increasingly using the technology to revolutionise their manufacturing processes.

Examples of just a few of these industries are as follows:

Aerospace

The ability to create lightweight components which are aerodynamic and can be formed in a variety of complex geometric shapes is paramount in importance to the success within the aerospace industry. Streamlining designs by being able to create components in a single piece (e.g. fuel nozzle), rather than having to join them together results in improved strength as well as better performance.

There are a huge number of applications within aerospace, with both interior and exterior parts benefitting from the technology. Functional engine parts such as turbine blades as well as interior parts such as cockpit equipment and seat belts can be made using additive manufacturing.

In aerospace, having lightweight parts is of particular importance. This isn’t just for their superior aerodynamic properties but also to save money too. Lighter designs burn less fuel and so are far more economical to run.

There are a number of other ways in which additive manufacturing helps to save money but for aerospace, the lightweight construction really is an important factor.

Electronics and semiconductors

Two industries which are bound tightly together, electronics and semiconductors have the capacity to achieve great things with the use of metal additive manufacturing. By combining the latest developments such as quantum dot LEDS, created via 3D printing techniques, and bioscience, there’s the possibility that superior prosthetics and medical aids could be created such as smart contact lenses and reactive prosthetic limbs.

Being able to print on 3d surfaces means that electronics no longer need bulky circuit boards or wires and cables; the entire package can be shrunk down into a micro size and made far more attractive for the commercial market.

Automotive industry

When it comes to car production, additive manufacturing is already used in a number of different applications across the body, interior and the engine.

However, the development of different materials to be used with processing such as laser melting and sintering leaves the way open for even greater utilisation in the future. Exhausts, bumpers and fluid valves are currently made using these methods, but as the range of materials increases, more complex parts such as engine components and electronics could be created.

Combining nanotechnology with additive manufacturing could create a greater scope too. Experts believe that this could make metals such as titanium strong and stable enough to create a dense material product.

Other material such as carbon fibre is already in widespread use, desirable for its light weight yet extreme toughness and strength.

Medical

The field of medicine is one which is constantly evolving and changing, battling to overcome the effects of age and disease on the human body.

Additive manufacturing has already proven to be a useful tool in the fight, allowing doctors to provide far more precise surgical outcomes and heal more easily.

Bodily implants are the perfect target for additive manufacturing as it requires absolute accuracy and a customised approach. Additive manufacturing makes this a far more cost-effective process because of the ease in which individually-designed prototypes can be created with just a few clicks of the mouse.

The medical industry extends to dentistry too, with crowns and bridges being manufactured via additive means for almost a decade already. The ability to create geometrically complex dentures from impressions and scans means a far more comfortable fit for the patient in the long term.

SPI Lasers and Selective Laser sintering

Our Lasers have been used in all types of metal additive manufacture, and we have delivered specific benefits to the process. In particular our Fiber Lasers bring benefits that can help manufacturers improve the quality of the printing, reduce costs, increase productivity and support quality control. Specifically we can provide the following process performance advantages:

  • Back reflection protection.
  • Fast temporal response with high stability.

 

Pulse shaping

  • Faster pulse rise times – shorter pulses deliver higher throughput and finer processing.
  • Power stability at switch on leading to less instability seen in work-piece.
  • Temporal pulse shaping an advantage as the process uses individual pulse in ‘point & shoot’ or continuous vector mode.
  • Back reflection protection because even for powders some users report issues.
  • In process monitoring. Using the back reflection signal from PIPA fibre provides a unique opportunity for real time non-invasive process monitoring.

For more information please see our selective laser sintering and melting page.

Why choose SPI Lasers?

We are the experts in the field of metal additive manufacturing and understand what you need from our Lasers to get the very best results. Our Lasers deliver pinpoint accuracy and are used in a number of different industries, from aerospace to medicine, consistently performing at the top of the field.

Additive manufacturing is one of the brightest new prospects and an industry which is set to continue to develop rapidly. Our Lasers have a proven track record of delivering excellent results within a variety of additive manufacturing processes.

To find out how we can help your metal additive manufacturing please contact us on 01489 779 696 or complete our online enquiry form. Also checkout our FAQs page.

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