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Metal 3D Printing & Additive Manufacturing

Understanding Surface Finish in Metal 3D Printing

Posted by 3DEO on Jun 4, 2018 1:13:21 PM

While metal AM brings with it a host of positive advantages, it’s important to understand the realities of as-printed surface roughness. This understanding will help design/engineering teams understand the costs associated with bringing 3D printed parts to a suitable finish.

Metal additive manufacturing is quickly making a name for itself as an up-and-coming manufacturing technology. The shift in transitioning from traditional manufacturing to metal 3D printing is being driven by a variety of advantages, including product-development flexibility and the ability to produce parts so complex they’d be impossible using conventional methods. While these positives are significant, there’s one area in which metal AM has historically struggled relative to other techniques: surface finish.

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Topics: cost, Metal AM Processes, Surface Finish

Low-Cost Production Metal 3D Printing: Intelligent Layering®

Posted by 3DEO on May 24, 2018 1:56:02 PM

Overview of Intelligent Layering®

The first metal AM technology competitive with traditional manufacturing

Intelligent Layering® is the only metal 3D printing technology that beats traditional manufacturing in cost, quality, and turnaround. Buyers struggle to source small, complex metal parts due to high up-front costs, long lead times, and locked-in designs. 3DEO’s patented technology solves this by competing on price and quality with no up-front costs, short lead times, and unlimited design freedom.

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Topics: Metal 3D Printing, additive manufacturing, Metal AM Processes

Intro to Metal Additive Manufacturing (AM) Processes - Material Jetting

Posted by 3DEO on Mar 27, 2018 9:37:52 AM

Overview of Material Jetting in Metal 3D Printing

Material Jetting is relatively new and similar to binder jetting, with one key difference -- instead of a binder being jetted through the printhead, a metallic material is jetted. This material is jetted onto the build tray directly using either a continuous jetting or Drop on Demand (DOD) process. The jetted metal is deposited on the build tray in the cross section of the part for that layer. This process continues as it builds up layer after layer. The resulting part still needs to be sintered in a furnace to achieve final part density. Previously, material jetting was limited to plastics and polymers, but recent advances have seen new companies attempting to commercialize the process for metals. XJet currently shows the most promise for material jetting with its patented NanoParticle Jetting technology and recently shipped its first commercial machine to a customer.

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Topics: Manufacturing, Design for 3D Printing, Metal 3D Printing, additive manufacturing, Metal AM Processes

Metal 3D Printing Processes - Directed Energy Deposition (DED)

Posted by 3DEO on Mar 22, 2018 4:00:02 PM

Overview of Directed Energy Deposition in Metal AM

Directed Energy Deposition (DED) is an additive manufacturing process where metal wire or powder is combined with an energy source to deposit material onto a build tray or an existing part directly. Parts chosen for DED are typically large without the need for tight tolerances. DED methods are capable of building very large parts and are popular because of the rapid deposition speed. Because it closely resembles welding, DED is commonly used to repair and maintain existing parts. DED machines usually mount a nozzle on a multi-axis arm, which then deposits the metal feedstock to the surface. When used with 5 or 6 axis machines, the material can be deposited from nearly any angle and is melted upon deposition with a laser or electron beam. This process means DED can be used to build objects very quickly and is only limited in size by the reach of the robotic arm.

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Topics: Manufacturing, Design for 3D Printing, Metal 3D Printing, additive manufacturing, Metal AM Processes

Metal 3D Printing Processes - Metal Extrusion FFF/FDM

Posted by 3DEO on Mar 13, 2018 10:38:02 AM

Overview of Metal Extrusion for 3D Printing

Metal extrusion in additive manufacturing is a fairly new process. Similar to the wildly popular plastic-based FDM process, filament is heated and drawn through a nozzle and then deposited layer-by-layer. This filament is a combination of thermoplastic material and metallic particles. The nozzle moves in the x and y axes across the part for a given layer. The build platform then lowers to make room for new layers. After the part is complete, it is placed into a sintering furnace to burn out the remaining plastic and sinter the metal particles together. Extrusion-based additive manufacturing has been widely used for plastics and polymers, but only recently has developed to create metal parts.

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Topics: Manufacturing, Metal 3D Printing, industry trends, additive manufacturing, Metal AM Processes

Metal Additive Manufacturing (AM) Processes - Binder Jetting

Posted by 3DEO on Mar 5, 2018 11:20:30 AM

Overview of Binder Jetting

Binder Jetting is a powder bed process that utilizes inkjet technology and a binding agent. The liquid binder is used to “glue” the metal powder together within and between layers. A layer of metal powder is first rolled onto the build tray, and then an inkjet print head moves along the x and y axes and deposits binder in the shape of the part for each respective layer. After each layer is created, the build platform is lowered incrementally to make room for the next layer. The part being printed is supported within the powder bed by the unbound powder, which is then removed to complete the process. The result is a “green part” which then needs to be placed in a sintering furnace to achieve final part density.

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Topics: Manufacturing, Metal 3D Printing, industry trends, additive manufacturing, Metal AM Processes

Intro to Metal 3D Printing Processes - Powder Bed Fusion (DMLS, SLS, SLM, LMF, DMP, EBM)

Posted by 3DEO on Feb 27, 2018 11:17:35 AM

Overview of Powder Bed Fusion - Metal 3D Printing

Powder Bed Fusion is a popular technique for metal additive manufacturing and includes two main technologies: Laser Sintering and Electron Beam. These techniques are grouped together since they each begin with a layer of metal powder being rolled onto the build tray, and then an energy source (laser or electron beam) fuses or melts the powder into deliberate 2D designs. These 2D layers are fused on top of each other to create the 3D object. Electron beams produce more energy than lasers and are chosen to fuse the highest temperature metal superalloys for parts used in extreme conditions such as jet engines and gas turbines.

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Topics: Manufacturing, Metal 3D Printing, additive manufacturing, Metal AM Processes