ADDITIVE MANUFACTURING
for processing materials such as copper, aluminium and stainless steel. These lasers can be used to achieve higher build rates in such materials with minimal post- processing required. For certain stainless steel parts, laser firm Nuburu was able to achieve build rates twice that of a standard infrared laser. UV lasers: UV lasers
Laser-based AM is now being used to produce highly robust parts such as heat exchangers, impellers and engine mid frames (above) across a range of industries
g
selectively curing and solidifying the photopolymer resin. The laser beam is focused in a predetermined path and the whole cross-sectional area of the model is scanned, so the produced part is fully solid. After printing, the part is not fully cured and requires further post- processing under UV light if very high mechanical and thermal properties are required.
Types of lasers used in AM A wide variety of lasers are used across the different AM processes. Fibre lasers: Widely deployed
in laser manufacturing, infrared fibre lasers are well-suited to laser-based AM due to their high beam quality, power density, energy efficiency, versatility, and reliability. Their excellent beam quality enables them to produce a very small, focused spot size. This is crucial for AM applications, where high- precision is required to produce complex geometries and fine details. The small spot size allows for greater control over the melting and solidification of the material, resulting in parts with high accuracy and smooth surface finish. Green lasers: Green lasers are starting to see uptake for
the AM of reflective metals such as copper, where their wavelength is absorbed considerably more than infrared lasers – as is the case with blue lasers (below). Their high beam quality enables them to be focused to a small spot size that facilitates the production of complex structures for parts such as gas coolers, fluid mixers, semiconductor coolers, shaft inductors and heat exchangers. Blue lasers: Similar to green
lasers, blue lasers are also beginning to see uptake in AM,
are commonly deployed in stereolithography, where they are used to cure a photosensitive resin layer-by-layer to produce a 3D part. The high-energy output of the UV laser allows for rapid curing of the resin, which leads to shorter processing times. In addition, the laser can be focussed to a very small spot size, enabling it to deliver parts with exceptional resolution and detail.
Industries served by laser- based AM Laser-based AM is being used in a plethora of industries to produce a wide variety of parts. In the aerospace industry,
for example, it is being used for the manufacture of fuel nozzles, ducting, heat exchangers, parts for landing gear, and turbine blades and other engine parts. Rocket thrust chambers and other propulsion components are also now being produced with laser-based AM. In the automotive industry, laser-based AM is being deployed for the production of: pistons, valves and crankshafts; transmission components such as gears, shafts, and housings; exhaust components such as manifolds and catalytic converters; brake components such as callipers, rotors, and brackets. It can also be used for creating moulds, jigs, and fixtures for other manufacturing processes. It should be noted, however, that in both of these industries, laser-based AM is only just starting to be certified for use in commercial applications. In the medical industry,
Laser-based AM is now being used to produce durable aerospace components such as this rocket nozzle chamber
36 LASER SYSTEMS EUROPE THE 2023 GUIDE TO LASER SYSTEMS
laser-based AM can be used to create customised orthopaedic implants, such as hip and knee implants, as well as dental implants. Such processes enable the creation of complex,
patient-specific parts, which can help to reduce recovery times. It can also be used to produce prosthetics, surgical tools and drug-delivery devices. Laser-based AM is being
deployed in the electronics industry to create printed circuit boards (PCBs) with higher precision and finer features than those produced with traditional manufacturing methods. It can also be used to create electronic components, such as antennas, sensors and transistors. In the energy industry,
laser-based AM can be used to create and repair parts for gas and wind turbines such as blades, vanes and internal
“AM is a powerful technology transforming the manufacturing landscape across a wide range of industries”
cooling channels. It is also being used to produce numerous other critical components such as impellers, valves and heat exchangers, each of which deliver the high reliability and robustness required for the demanding environments of energy production. In conclusion, laser AM is
a powerful technology that is transforming the manufacturing landscape across a wide range of industries. The ability to create highly customised, precise, and complex parts using this technology is enabling companies to improve the performance, efficiency, and reliability of their products, while also reducing costs and lead times. l
For more information about laser-based additive manufacturing, visit:
www.lasersystemseurope.com/ applications/additive- manufacturing
@LASERSYSTEMSMAG |
WWW.LASERSYSTEMSEUROPE.COM
SLM Solutions
Velo3D
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