Additive Manufacturing

It is an industrial grade system for 3D Additive Manufacturing of small and medium sized metal structures. It is characterized by compact size , high build precision, user friendliness, and robustness. Our system uses Co-Axial Blown Powder Technique ( LMD ) to produce fully dense metal structures, and provides the standard for building complex parts.

The system consists of SPI fiber laser, Willowborg Industrial Machine Platform, FESZL Core Moulding Unit and CNC System. This system is suitable for building high value metal parts in small quantities. It can be widely used for aerospace, medical implants, mould manufacturing, research and many other applications

[Image: Micro Machining]
Dimensions 2000 x 1500 x 1800 mm
Build Envelope 1000 x 600 x 350 mm
Weight ~700 kg
Laser Model SPI
Laser power 1000 W
Build accuracy 0.05mm
Process gas N2/Ar
Control system SINUMERIK 828D
Slicing Software Met-Build 2017
CAD Software ProE, SolidWorks, UG. CATIA. AUTOCAD
Deposition Rate 50-10g/min
Core Process Assembly FESZL Cladding Assembly
Additive Manufacturing System
Key Features
  • Large capacity work area with accessibility for large parts, ergonomic system with enhanced user-friendliness.
  • The proprietary FESZL Laser Cladding Head increases build dimensional stability and repeatability and improves throughput and final part quality.
  • Software efficiently creates process parameters and enables simple "push-button" operation.
  • The machine is designed to be portable. It can be fitted to work in almost manufacturing environment.
  • A variety of Cladding Heads are available to meet any specific application requirements.
  • The machine works with metal powder of grain size of 50-150 microns which can be recycled several times,offering significantly lower expenses on consumables&overall operational cost.
  • Anaerobic enclosures are available for down to < 10 ppm Oxygen, for processing of reactive alloys such as Titanium with Argon (99.999%)
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System Characteristics & Advantages

It can produce parts in any weldable metal, from a range of elemental, pre-alloyed or mixed powders with either spherical of irregular shaped grains with grain sizes of 50-150 microns.

For Titanium and other reactive metals, the machine can be upgraded to an anaerobic chamber (Oxygen content of <50 PPM as standard, and down to <10PPM upon request) with an Argon atmosphere.

Alloy Grade
Titanium TC4
TA15
BT22
Nickel Based Inconel 625
Inconel 718
Co - Cr Stellite 21
Stainless Steel 304
316
347
Tool Steel H13
JG4246
Aerospace K424
Comparison between Blown Powder & Powder Bed Systems
Blown Powder Vs Powder Bed
MLS System Model A Typical Powder Bed Machine
1000x 600x350 Build Envelope (L*W*H) 250 x 250 x 325
SPI 1000W Laser Model Ytterbium Fiber Laser, 400 Watts
FESZL Optical Scanning System F-theta lens, high speed scanning lens
Up to 1m/s Scanning Speed Speed up to 7.0m/s, accuracy up to 6 microns
1.5-0.2mm Layer Thickness 0.1-0.02 mm
60-0 g/min Build Rate 20-5 cc/hr
2000 x1500 x 1800 mm Machine Dimensions (L*W*H) 2500x 1300 x 2190mm
3.2m x 2.5m x 2.5m Recommended Installation Space (L*W*H) 4.8m x 3.6m x 2.9m
~ 700 Kg Weight ~ 1,250 Kg
ProE/ Solid Works/Catia CAD Software Proprietary software
MetBuild Slicing Software Proprietary software
STL file Data Format STL file
Control & Software
Modeling Software:

Any modeling software that can generates SAT or IGES file format can be used, such as: ProE, CATIA, SolidWorks, UG, Inventor, etc. CAD software can be supplied on request to client requirements

Control Panel:

SIEMENS SINUMERIK 828D is a panel-based CNC system. CNC, PLC, Operator Panel and 6-axis drive control (standard) are integrated in one unit.

This configuration eliminates the hardware interface between the CNC circuit board and the operator panel, thus improving the system's durability and provide ease of operation. Extra customised functions can be added by the customer. Siemens provides good customer service around the world. Most of Metlas working functions can be directly accessed and modified here on the panel.

[Image: Micro Machining]

The MetBuild software is a proprietary programming software that converts 3D CAD drawings into CNC codes that can directly drive Metlas or other AM systems to build parts. MetBuild consists of three main modules:

  • WorkTable:
    An User-friendly environment where a CAD file can be imported, inspected and manipulated before slicing.
  • 3D Slicer:
    Slicing 3D geometry into a finite number of 2D layers, each filled with vector paths.
  • EASY LMD:
    A postprocessor that generates and edits G-Codes from the Vector paths. The G/M Codes can be saved as text files and then transferred to the controller unit of an AM/Cladding machine.

The MetBuild software can be purchased along with Metlas Systems, or individually, to be used on clients' existing Blown Powder AM/Cladding machines.

Samples:
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