July_August_AMP_Digital

A D V A N C E D M A T E R I A L S & P R O C E S S E S | J U L Y / A U G U S T 2 0 1 9 2 8 F or years, the 3D printing industry— especially metal 3D printing—was challenged by inconsistent print out- comes that inhibited widespread adop- tion. Now, as major companies have embraced the benefits of additive man- ufacturing (AM) and started integrating it into their supply chains, the technol- ogy has advanced to a key production solution. Additive metal technology is ex- panding manufacturing possibilities by enabling new designs and improved out- comes not previously possible with tradi- tional methods. METAL PRINTING METHODS Metal 3D printing utilizes metal materials, either powdered or spooled, to additively build a geometry layer- upon-layer. The chief methods for met- al 3D printing can be summarized in four technologies: binder jetting, sheet lamination, directed energy deposition, and powder bed fusion. Binder jetting is defined as an ad- ditive manufacturing process in which a liquid bonding agent is selectively de- posited to join powder materials. This process is also known as ink jet, XJet, digital metal, and binder jetting. Sheet lamination is described as an additive manufacturing process in which sheets of material are bonded to form a part. Directed energy deposition is an addi- tive manufacturing process in which focused thermal energy is used to fuse materials by melting as they are being deposited. This method is also referred to as laser engineered net shaping, di- rected light fabrication, 3D laser clad- ding, and direct metal deposition. Finally, powder bed fusion is de- fined as an additive manufacturing process in which thermal energy selec- tively fuses regions of a powder bed. This process is also called direct metal laser sintering, selective laser melting, direct metal laser melting, laser cus- ing, and electron beam melting. Pow- der bed fusion (PBF) is currently the most common form of metal AM and perhaps the most misunderstood. PBF can create very accurate parts, and to- day’s high-precision lasers and electron beams make it possible to manufac- ture intricate parts while offering the broadest range of materials to work with. Due to its prevalence and indus- try impact, the future is promising for laser-based PBF due to the number of companies making systems that em- ploy this technology. WHY COMPANIES TURN TO AM Additive manufacturing is often considered a one-step manufacturing process with no setup and tooling costs. Costs associated with produc- tion are incurred for the parts them- selves, no matter how small the batch. Design changes to components can be easily implemented and printed one-off without incurring retooling costs and lead times. Companies can redesign, print, and install parts in days, often saving significant time and money. Because 3D printing builds com- ponents in layers, designers can create complex geometries not possible with traditional manufacturing. Engineers take advantage of the design freedom to reimagine multiple component parts as one contiguous design. Consolidat- ing multi-component designs and us- ing high-strength metals often results in much lighter and stronger parts. In addition, manufacturer-specific ad- aptations and small production runs TRENDS WATCH: METAL ADDITIVE MANUFACTURING Metal 3D printing is expanding manufacturing possibilities by enabling new designs and improved outcomes. TECHNICAL SPOTLIGHT