Usually, we're telling you about bigger 3D printer build volumes, not smaller ones. But this is a bit different. Optomec has taken a highly sophisticated 3D printing process for metals and made it available in a smaller machine.
Engineers have been producing metal components, not just prototypes, for several years using Optomec's version of selective laser sintering (SLS), which the company calls LENS (Laser Engineered Net Shaping). The components built have been relatively large, with a process work envelope of 900 mm x 1,500 mm x 900 mm (35.43 inch x 59.0 inch x 35.43 inch) for the company's largest machine, the 850-R. That one deposits material such as standard steels, titanium, and nickel alloys at up to 500 g/hr (1.1 lb/hr).
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Optomec's original, large 850-R system is used for making final production parts or prototypes, and repairing metallic components, such as this casing. (Source: Optomec)
Optomec says that for many applications the mechanical properties of components built with the process are equivalent to those of wrought metals. For example, independent testing has shown that the fatigue strength of Ti 6-4 matches the fatigue strength of wrought annealed material. Yield strength and tensile strength of the 3D-printed material were actually better at 973 MPa and 1077 MPa versus 834 MPa and 973 MPa, respectively, for Ti-6Al-4V, a titanium/aluminum alloy. Among other things, Ti-6Al-4V alloys are used for structural components on commercial aircraft.
Originally developed at Sandia National Laboratories, the LENS process has been used for prototyping and manufacturing military and aerospace components, as well as medical instruments and implants. It can be used for adding layers of metals to an existing component to improve its wear resistance, or add features to large cast components, such as a flange or boss. The process has also been optimized for repairing military and aerospace metallic components, such as restoring their inner diameters or inside blind holes. (Watch a video demonstrating the process below.)
The new machine, the LENS 450, is built with the same basic technology, but it has a much smaller process work envelope of 100 mm x 100 mm x 100 mm (3.94 inch x 3.94 inch x 3.94 inch). It also has a much slower (about 6.25 times slower) maximum deposition rate of 80 g/hr (2.82 oz/hr). It comes with a 400W fiber laser, a motion control system, and proprietary process control and part preparation software. The machine prints titanium, stainless steel, cobalt chrome, and superalloys.
So why would anyone want one of these? Interestingly, Optomec says it has developed this model to help proliferate the use of metals in additive manufacturing. The company is aiming the printer at university mechanical and materials engineering departments and labs, for the purpose of training the next generation of engineers in AM, and specifically, AM with metals.
The first machine will be delivered to the University of Pittsburgh's department of mechanical engineering and materials science, for use in the department's advanced manufacturing program. The university is a member of the federally sponsored National Additive Manufacturing Innovation Institute (NAMII). Wouldn't it be interesting if this became a trend?
@Ann – All technology comes at a high price most of the time, later when there is competition in the market the manufacturers are forced to bring down the prices for the product to survive in the market.
@78RPM - Yes model builders will definitely find this very useful; it helps them save their time. Now it's just a matter of designing the 3D model and the printer will do the rest for you, whereas sometime back you need to craft the object.
@David – I think we should give it few more days for the product to establish its self in the market and automatically the prices will fluctuate with the competition. I am sure it would not be a monopoly or oligopoly, as there are many manufactures waiting to enter into the market.
@Ann - all devices come in small sizes with same or better performance, I think the same concept applies here. 3D printer manufacturers making smaller versions of their machines with smaller build volumes that still can use complex 3D printing technologies
78RPM makes an interesting point about metals printers and service bureaus. Right now, these machines/processes and their materials are probably way too pricey for that. They were developed to serve high-end applications in industrial, military and aerospace markets, so pricing is on a very different scale from anything aimed at consumers. This is an important point to keep in mind about 3D printing/AM--there are two very different ends of the industry.
This smaller printer would be useful for model builders (including model engines) if the price is right. Of course, 3D service bureaus would be an option. I see news today that Stratasys plans to grow by acquiring companies that make 3D metals printers.
These new 3D-printing technologies and printers include some that are truly boundary-breaking: a sophisticated new sub-$10,000, 10-plus materials bioprinter, the first industrial-strength silicone 3D-printing service, and a clever twist on 3D printing and thermoforming for making high-quality realistic models.
Using simulation to guide the drafting process can speed up the design and production of 3D-printed nanostructures, reduce errors, and even make it possible to scale up the structures. Oak Ridge National Laboratory has developed a model that does this.
Engineers need workhorse materials with beefy mechanical properties for industrial designs made with 3D printing. Very few have been designed from the ground up for additive manufacturing, but that picture is beginning to change.
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