#metal additive manufacturing

[rubylobo15]

Explore the Future of Manufacturing with Metal Additive Printing

Discover the cutting-edge possibilities of metal additive manufacturing as a journey into the future of manufacturing. At Phillips Corp, they are revolutionizing the industry through advanced technologies. Explore the innovative world of metal additive printing, where precision and efficiency unite to shape tomorrow's manufacturing landscape. Browse through their website to know more - https://www.phillipscorp.com/

[innovae3d-pvt-ltd]

Case Study on Aerospace: Cable Routing Mount for The Latest Airbus Model Using Metal Additive Manufacturing

1. About Project – A Cable Routing Mount

A cable routing mount is required for the power supply and data transportation of a camara located in the vertical stabilizer to provide the view of the outside to the passengers and orientation of the ground the pilots. Conventionally manufactured cable routing mount consisted of 30 individual parts combination of sheet metal parts and many rivets and total manufacturing time was 70 days.

This project’s requirement was the production of functionally operational cable mount parts in the lead time of only just two weeks. The project involves analysis of the part, optimization of the design, and final production in that short time frame with compliance with the strict requirements for subsequent aviation industry certification.

2. Metal AM Cable Routing Mount – Solution and Results

Considering the situation – like part’s functionality, complex structure, and time frame – metal Additive manufacturing was the ideal solution. And, Sogeti High Tech followed the tried and tested development process to manufacture this part with metal AM (DMLM technology).

The design freedom offered by metal AM helps in integrating the whole assembly in a single part, hence, weight saving without affecting its functional requirement. Dedicated software used to re-design (topology optimization) the part.

The AlSi10Mg material for the cable mount was considered which ideal for thin-walled and complex structure.

Final part printing was done on EOS M 400 machine with the layer thickness of 90 µm. Final required time to manufacture this cable mount was 19 hours against 70 days for conventional manufacturing methods. Hence, reduction in production time by 90% is achieved with metal AM (DMLM) technology.

New designed cable mount resulted in significant weight reduction, i.e., from 452 gm for original part with conventional manufacturing to 317 gm for additively manufactured cable mount.

In addition to above mentioned results, i.e. lead time and weight reduction, metal AM offers others various other benefits as a consequence of these benefits and those are reduction in post processing cost, no longer need be held in stock, reduced development time, and reduced fuel consumption as a result of weight reduction.

About Us

We are Innovae3D company specialized in producing the parts using metal 3D printing, i.e. Direct Metal Laser Melting (DMLM) technology, for various applications. Innovae3D is AS 9100 and ISO 9001 certified company.

Innovae3D provides the complete solutions (starts from designing, printing, post-processing, to quality control and assurance) for tooling, automotive, aerospace, defense, consumer electronics, medical, oil and gas, and industrial sectors.

[metal3d]

metal parts manufacturing companies

[materialsscienceandengineering]

Residual Stress in Metal Additive Manufacturing

One manufacturing process in particular that needs to pay close attention to residual stresses is the fairly new field of metal additive manufacturing (AM). Most metal AM processes involve high thermal gradients and fast cooling rates, which can lead to high residual stresses in parts. These stresses can be severe enough to cause failure even during the build process, or immediately upon cooling, before parts have even been removed from the build plate. Residual stresses have been said to be the most common cause of catastrophic failure of metal AM parts. As such, heat treatments before parts are removed from the build plate are common, including heat treatments known as 'stress relieving'.

Sources/Further Reading: (Image source - Metal AM) (2022 article)

[3dprinterchat]

Unveiling Aurora Labs' AL250: A Leap Forward in Metal 3D Printing

Australian innovator Aurora Labs steals the spotlight with its groundbreaking AL250 metal 3D printer launch at Formnext 2023. Buckle up for a ride through the realms of aerospace, defence, oil and gas, engineering, and bespoke production runs as we explore the incredible features of this cutting-edge technology. The AL250 Say goodbye to the RMP-1 and welcome the AL250, Aurora Labs‘ latest laser…

[tmr-blogs2]

Metal Powders for Additive Manufacturing Market to reach US$ 2.7 billion in 2031, Expanding at a CAGR of 21.5%

Additive manufacturing, also known as 3D printing, has revolutionized traditional manufacturing processes by offering greater flexibility, customization, and efficiency. At the heart of this transformative technology lies metal powders, essential materials enabling the production of complex, high-performance components across various industries. The Metal Powders for Additive Manufacturing Market is poised for significant growth between 2023 and 2031, driven by advancements in additive manufacturing technologies and increasing adoption across diverse sectors.

The worldwide metal powders for additive manufacturing market was estimated to be worth US$ 466.3 million in 2022. It is expected to grow at a CAGR of 21.5% from 2023 to 2031, reaching US$ 2.7 billion by the end of 2031.

Additive manufacturing, also known as 3D printing, has established itself as a game-changing technology that allows for the production of complicated components with unprecedented design freedom. This feature has presented new options for companies looking to improve their product's effectiveness, productivity, and flexibility.

Download Sample PDF Copy at: https://www.transparencymarketresearch.com/sample/sample.php?flag=S&rep_id=33197

Market Segmentation

By Service Type: The market can be segmented into powder bed fusion, directed energy deposition, binder jetting, and others, reflecting different additive manufacturing techniques employed.

By Sourcing Type: Segmentation by sourcing type includes atomization, deposition, and others, representing the methods of metal powder production.

By Application: Metal powders find applications in prototyping, tooling, functional parts production, and more, catering to diverse needs across industries.

By Industry Vertical: Segments include aerospace, automotive, healthcare, consumer goods, and others, showcasing the wide-ranging utilization of metal powders in additive manufacturing.

By Region: The market is geographically segmented into North America, Europe, Asia Pacific, Latin America, and Middle East & Africa, with each region contributing to the overall market growth differently based on regional factors and industrial landscapes.

Regional Analysis

North America and Europe are anticipated to dominate the Metal Powders for Additive Manufacturing Market owing to established manufacturing industries, robust research and development infrastructure, and supportive regulatory frameworks. However, Asia Pacific is expected to exhibit the highest growth rate during the forecast period, driven by rapid industrialization, increasing investments in additive manufacturing technologies, and the presence of key market players in countries like China, Japan, and South Korea.

Market Drivers and Challenges

Drivers:

Advancements in additive manufacturing technologies

Growing demand for lightweight and high-performance components

Increasing adoption of metal additive manufacturing in various industries

Customization and design freedom offered by additive manufacturing processes

Challenges:

High initial investments and operational costs

Limited material options and process control challenges

Regulatory constraints and intellectual property issues

Lack of skilled workforce proficient in additive manufacturing techniques

Market Trends

The emergence of novel metal powder compositions tailored for specific applications

Integration of artificial intelligence and machine learning for process optimization

Adoption of hybrid manufacturing combining additive and subtractive processes

Shift towards sustainable and recyclable metal powders for additive manufacturing

Future Outlook

The Metal Powders for Additive Manufacturing Market is poised for exponential growth in the coming years, fueled by ongoing technological advancements, expanding application areas, and increasing investments in research and development. The market is expected to witness a surge in demand for metal powders with superior properties, paving the way for new opportunities and innovations in additive manufacturing.

Key Market Study Points

Analysis of market dynamics including drivers, challenges, opportunities, and trends

Assessment of market size and growth potential across different segments and regions

Evaluation of competitive landscape and key market players

Examination of recent developments, partnerships, mergers and acquisitions, and product launches in the market

Procure Complete Report (305 Pages PDF with Insights, Charts, Tables, and Figures) https://www.transparencymarketresearch.com/checkout.php?rep_id=33197<ype=S

Competitive Landscape

Key players operating in the Metal Powders for Additive Manufacturing Market include:

Sandvik AB Renishaw plc. Praxair Technology, Inc. BÖHLER Edelstahl GmbH & Co KG Aubert & Duva ATI RIO Tinto

These companies are actively engaged in strategic initiatives such as product development, partnerships, and collaborations to gain a competitive edge in the market.

About Transparency Market Research

Transparency Market Research, a global market research company registered in Wilmington, Delaware, United States, provides custom research and consulting services. Our exclusive blend of quantitative forecasting and trends analysis provides forward-looking insights for thousands of decision-makers. Our experienced team of Analysts, Researchers, and Consultants use proprietary data sources and various tools & techniques to gather and analyze information.

Our data repository is continuously updated and revised by a team of research experts so that it always reflects the latest trends and information. With a broad research and analysis capability, Transparency Market Research employs rigorous primary and secondary research techniques in developing distinctive data sets and research material for business reports.

Contact:

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[wipro-3d]

Delivering Excellence with Direct Metal Laser Sintering (DMLS) |Additive Manufacturing Solutions| Wipro-3D

Wipro 3D offers additive manufacturing solutions based on direct metal laser sintering(DMLS) technology. Which helps to deliver exceptional accuracy, speed, and quality.

Read more:

[objectify91]

Objectify is the 3D printing and Additive Manufacturing (AM) company in India, providing complete range of Additive manufacturing solutions in Plastics, as well as Metals including Titanium (Ti6Al4V), Aluminum (AlSi10Mg), Maraging Steel 1 (MS1), Stainless Steel 316L (SS-316L), etc.; all in-house through state of the art, manufacturing set-up.

We have successfully delivered various projects to leading Automotive, Aerospace & other companies, including HAL, BorgWarner Inc., TATA Group Companies, Mahindra Group Companies, Wipro, Havells, Philips etc.

[theankita1996]

The Insight Partners published latest research study on “3D Printing Metal Market Size, Industry Share, Trends and Forecast to 2028- 3D Printing Metal Market Forecast to 2028 – COVID-19 Impact and Global Analysis – by Metal Type (Titanium, Nickel, Stainless Steel, Aluminum, and Others), Form (Powder, Filament, and Others), End-Use Industry (Aerospace & Defense, Automotive, Medical, Construction, and Others), and Geography," the global 3D printing metal market size is expected to grow from USD 4.5 billion in 2021 to more than USD 13 billion by 2028 at a CAGR of 16.5% between 2022 and 2028.

[innovae3d-pvt-ltd]

The Advantages of Conformal Cooling in Reducing Cycle Time

Evaluating the efficiency of injection moulding is dependent on its productivity and quality of component. The proximity of cooling channels decides the cooling efficiency. Even a slight variation in the distance between two cooling channels can cause uneven heat dissipation. This result in increased cycle time, sink marks, part warping, reduced tool life due to heat stress and internal part stresses.

Importance of Reduced Cycle Time

The pace of the injection moulding machine in your factory will decide how much profit your company will make. Cooling takes a significant portion of cycle time, which is why it also has major focus when trying to improve business operations.

Conformal cooling tooling has proven effective in reducing cycle time, by as much as 70% in some cases. Till a few years ago, conventional manufacturing techniques could create cooling channels but this usually limited freedom of design and upped the cost of manufacturing in many applications. However, using additive manufacturing (AM), or 3D printing, as it is popularly known, helps you to experiment with fewer limitations, and reduces cycle time effectively.

Using DMLS, it is possible to design and develop extremely complicated geometric shapes and complex functional components in the most cost-effective manner. In essence, direct metal laser sintering lets you insert cooling channels without drilling, thus making the design more feasible and functional.

Points to Consider when using Conformal Cooling Technique

There are four main principles that guide the functioning of conformal cooling method.

1. Wall Thickness

Cooling time exponentially increases with increase in thickness of walls of the component being manufactured using DMLS conformal cooling method. For instance, a component with a 1-mm thick wall takes around 5 seconds to cool down while a component with walls 5-mm thick may take as much as 40 to 75 seconds.

2. Thermal diffusion

Thermal diffusion is the ratio of thermal conductivity to heat capacity. This factor is vital because when thermal diffusion of a material is low, the longer it takes to dissipate heat.

3. Mould temperature

High mould temperatures allow lowering of pressure during the filling phase. This helps to get a better surface finish on components and can also increase cooling time multi-fold.

4. Pitch and Depth

The depth, size and spacing of cooling channels should cause the temperature to change across the mould surface by 5 to 10 degree Celsius. Increasing the number of cooling channels placed close together near the surface accelerates cooling and also maintains temperature uniformity.

Benefits of Conformal Cooling in Reducing Cycle Time

Conventional cooling methods often cause shrinkage on core side, creates gaps in the part with limited space and the channels in the core are likely to experience higher temperature exchange.

To remedy this, the best way is to use two thermal controllers, choosing a lower-conducting material for cavity and changing the distances between channels and cavity. This method works incredible well for numerous applications.

Here are the distinct benefits of using conformal cooling tooling for prototyping and manufacturing:

1. Less cycle time

Various studies have shown that conformal cooling can cut cycle time by as much as 70% as compared to traditional cooling channels.

2. Freedom of design

This technique helps designers to create smooth transitions and smaller diameter channels with elliptical or circular cross-sections. Conformal cooling helps to reach spaces not allowed with conventional cooling channels.

3. Better quality

With uniform temperature distribution through conformal cooling, it is possible to reduce risk of stress that can cause visual defects and deformation of design. This helps improve product quality noticeably.

Conclusion

Using conformal cooling technique, it is possible to not only reduce cycle time, but also improve product quality, create incredibly complex designs and control the functionality of components more effectively. Last, but not the least, conformal cooling eventually helps to improve your company’s profits.

[metal3d]

Veer O Metals was established in 1965. We are engaged in the manufacture of Stamped Parts, Precision Sheet Metal Fabrication Parts, Machined Components and Mechanical Assemblies. We have an in-house strong Mechanical Engineering and Manufacturing team for Design and Development, dedicated in providing high end design solutions which are industry specific.

We have established a strong client base at National and International level with our transparent and Global practices, and at the same time retaining robust quality management systems. By developing indigenously designed products of global standards for various sectors, we have added a new dimension to our already existing wide range of product manufacturing and assemblies.

With a core principle of innovation and enhanced technology, Veero always has been at the forefront in embracing the newest trends in the industry. Introducing first of its kind Metal Additive Manufacturing (Metal 3D Printing). Veero has augmented cutting edge manufacturing technology in the field of metal additive manufacturing. It is a Disruptive Technology, which is an automatic process of manufacturing objects (Parts, Prototypes, tools & even assemblies) directly from their CAD models without any cutter, tools and jigs & fixtures.

From inventions to innovations, energy responsibility to environment stewardship, Veer O Metals is well positioned to be a technology leader in manufacturing of sheet metal fabrication parts and mechanical assemblies.

We are proud to mention that we are the most preferred partner for our clients. We have state of the art manufacturing locations in India and Philippines.

Our core activities have been in:

Stamping Components

Precision Sheet Metal Fabrication Parts

Enclosures

Industrial and IT Racks

Mechanical Assemblies

Machined Components

Veer O Products

Metal Additive Manufacturing ( 3D Printing )

Our approach to manufacturing excellence entails stringent quality checks and continual improvements.

[reasonsforhope]

"Clothing tags, travel cards, hotel room key cards, parcel labels … a whole host of components in supply chains of everything from cars to clothes. What do they have in common? RFID tags.  

Every RFID (Radio Frequency Identification) tag contains a microchip and a tiny metal strip of an antenna. A cool 18bn of these are made – and disposed of – each year. And with demands for product traceability increasing, ironically in part because of concerns for the social and environmental health of the supply chain, that’s set to soar. 

And guess where most of these tags end up? Yup, landfill – adding to the burgeoning volumes of e-waste polluting our soils, rivers and skies. It’s a sorry tale, but it’s one in which two young graduates of Imperial College London and Royal College of Art are putting a great big green twist. Under the name of PulpaTronics, Chloe So and Barna Soma Biro reckon they’ve hit on a beguilingly simple sounding solution: make the tags out of paper. No plastic, no chips, no metal strips. Just paper, pure and … simple … ? Well, not quite, as we shall see. 

The apparent simplicity is achieved by some pretty cutting-edge technical innovation, aimed at stripping away both the metal antennae and the chips. If you can get rid of those, as Biro explains, you solve the e-waste problem at a stroke. But getting rid of things isn’t the typical approach to technical solutions, he adds. “I read a paper in Nature that set out how humans have a bias for solving problems through addition – by adding something new, rather than removing complexity, even if that’s the best approach.”   

And adding stuff to a world already stuffed, as it were, can create more problems than it solves. “So that became one of the guiding principles of PulpaTronics”, he says: stripping things down “to the bare minimum, where they are still functional, but have as low an environmental impact as possible”.  

...how did they achieve this magical simplification? The answer lies in lasers: these turn the paper into a conductive material, Biro explains, printing a pattern on the surface that can be ‘read’ by a scanner, rather like a QR code. It sounds like frontier technology, but it works, and PulpaTronics have patents pending to protect it. 

The resulting tag comes in two forms: in one, there is still a microchip, so that it can be read by existing scanners of the sort common within retailers, for example. The more advanced version does away with the chip altogether. This will need a different kind of scanner, currently in development, which PulpaTronics envisages issuing licences for others to manufacture. 

Crucially, the cost of both versions is significantly cheaper than existing RFID kit – making this a highly viable proposition. Then there are the carbon savings: up to 70% for the chipless version – so a no-brainer from a sustainability viewpoint too. All the same, industry interest was slow to start with but when PulpaTronics won a coveted Dezeen magazine award in late 2023, it snowballed, says So. Big brands such as UPS, DHL, Marks & Spencer and Decathlon came calling. “We were just bombarded.” Brands were fascinated by the innovation, she says, but even more by the price point, “because, like any business, they knew that green products can’t come with a premium”."

-via Positive.News, April 29, 2024

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Note: I know it's still in the very early stages, but this is such a relief to see in the context of the environmental and human rights catastrophes associated with lithium mining and mining for rare earth metals, and the way that EVs and other green infrastructure are massively increasing the demand for those materials.

I'll take a future with paper-based, more humane alternatives for sure! Fingers crossed this keeps developing and develops well (and quickly).

[materialsscienceandengineering]

North Carolina State University researchers have demonstrated a technique that allows people who manufacture metal machine parts with 3D printing technologies to conduct automated quality control of manufactured parts during the finishing process. The technique allows users to identify potential flaws without having to remove the parts from the manufacturing equipment, making production time more efficient. "One of the reasons people are attracted to 3D printing and other additive manufacturing technologies is that these technologies allow users to quickly replace critical machine components that are otherwise difficult to make outside of a factory," says Brandon McConnell, co-corresponding author of a paper on the work. "And additive manufacturing tools can do this as needed, rather than dealing with supply chains that can have long wait times. That usually means using 3D printing to create small batches of machine parts on demand." McConnell is an assistant research professor in NC State's Edward P. Fitts Department of Industrial and Systems Engineering.

Read more.

[3dprinterchat]

Desktop Metal Faces NYSE Scrutiny

Introduction: Hey folks, buckle up for some recent news from the stock market! You know, the kind that raises eyebrows and triggers a flurry of discussions? So, here’s the scoop: Desktop Metal has landed on the New York Stock Exchange’s (NYSE) radar due to a bit of a hiccup in its stock price. Let’s dive into the details and unravel what’s been going on. Desktop Metal’s NYSE Spotlight In a…