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moulds | Additive manufacturing Part quality is the top priority


3D printing has put additive manufac- turing centre stage in the mainstream media over recent years. However, while sharing the same basic concept, metal additive manufacturing is a world away from these consumer-oriented systems, says Dr Florian Bechmann, head of development at Germany-based Concept Laser. He says industrial users are very much focused on quality requirements and that needs the right combination of optics, mechanics and control technology and software. Concept Laser uses


two different tools to control build quality. QMmeltpool is an optical system that uses a camera and photo diode to continually monitor the melt pool to detect any variation in laser performance or dosing factor. QMcoating monitors the dosing of the powder in each layer, making automatic adjustments if over or underdosing is detected. Customer are also looking for ways


Rigth: Concept Laser head of development Dr Florian Bechmann says quality is the top priority for industrial metal


additive manufacturing


Below: From start to finish – Concept Laser metal powder and final part


to increase build speed. The company recently introduced its X-Line 1000R machine, which uses a


1000W laser and is claimed to offer the


largest build area of any metal additive manufactur-


ing system. The 1000R offers a build


envelope of 630mm by 400mm by 500mm and can build parts at a rate of up to 65cm3


will be looking to incorporate multiple lasers that will call for even more


However, Niavas sees the technology having a subtle


but more fundamental impact on the moulding industry in lifting some of the current process-based limitations on part designers. “The additive manufacturing process enables design-driven manufacturing as opposed to the manufacturing-driven design we normally see when using conventional design and manufacturing meth- ods,” he says. How quickly these changes filter through to the mouldmaking and moulding industry will depend, in part at least, on how effective additive manufacturing system producers are able to sell the benefits and reliability of the technology. “Market education is key here,” says Niavas. “A lot of mould makers still associate risk with a relatively new technology like ours. As a mould maker, one potentially wants to use products or solutions that are well-known, that have been on the market for a long time, and for which historical and statistical data are available.”


48 INJECTION WORLD | June 2014 /h. For the future, machine builders


complex optical constructions. Concept Laser is certainly confident about the future for metal additive manufacturing. The company announced last month it is building a 3,500m2


new


production hall at its plant at Lichtenfels in Germany, which will be ready for occupation in the autumn. The company says the new facility will allow it to up its production capacity to meet a growing order intake while allowing it to offer enhanced commissioning trials (a number of secure evaluation areas will enable customers to run confidential trials). ❙ www.concept-laser.de


As with any technology, understanding the additive


manufacturing process and how to adapt part designs to it requires building up a skill set and this cannot be done overnight, he says. As a consequence, many mould makers will work with an external service provider. But some mouldmakers are already integrat- ing the technology into their own operations. Germany-based Spritzguss + Formenbau Bergman is among the latest additions to the growing number of mouldmaking companies that have invested in their own additive manufacturing capability. It recently took delivery of an Eosint M280 machine from EOS, which it intends to use for production of its own mould tools and to offer an insert building contract service – the company is to become a service provider to EOS. “Not only can we employ the new metal system for


tool making on the premises but we can now also perform contract work for our customers, based on this new manufacturing technique,” says André Gerbert,


www.injectionworld.com


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