Says Concept Laser (UK agent ES Technology), previous solutions for AM machine and plant technology in the market all relied on ideas such as “more laser sources,” “more laser power,” “faster build rates” or “expansion of the build envelope sizes.”
This machine technology represented a “standalone” solution without any consistent integration into the manufacturing environment. Build job preparation and build job process proceeded sequentially.
Says Dr Florian Bechmann, head of R&D at Concept Laser: “In essence, it [the factory building kit] is about splitting up build job preparation/build job follow-up processing and AM in any number of combinable modules. With comparatively large build envelopes, build jobs can be carried out with a time delay.
“The intention is that this should drastically reduce the ‘downtimes’ of previous stand-alone machines. There is plenty of potential here for improving the level of added value in the production chain. In contrast to purely quantitative approaches of previous machine concepts, we see here a fundamentally new approach for advancing industrial series production one step further.”
Production is, says Concept Laser, “decoupled in machine terms from the preparation processes”. The time window for AM production is increased to a “24/7 level,” meaning that there is higher availability of all components, with automated flow of materials reducing the workload for the operators. In addition, the new machine concept has a new type of 2-axis coating system that enables return of the coater in parallel with exposure, resulting in a “considerable time saving during the coating process”.
Interfaces integrate the laser melting machine into traditional CNC machine technology and also with downstream processes (post-processing / finishing).
Adds Bechmann: “The [AM] build rates have increased enormously, thanks to the multi-laser technology. The build envelope sizes have also experienced considerable growth. We now want to use an integrated machine concept to highlight the possible ways that the approaches of ‘Industry 4.0’ can change AM as the manufacturing strategy of the future. There is plenty of potential here to increase industrial added value and enhance suitability for series production.”
The factory building kit comprises a modular process station with integrated laser sources, process gas management and filter technology. In addition, the machine solution will be available with one, two or four laser optics featuring laser power from 400 to 1,000 W, and redundancy of the lasers will ensure that, if one laser fails, the remaining three lasers will still cover the entire build plate.
An associated modular handling station has an integrated sieving station and powder management, and can be linked to two process stations to create a cell.
Ultimately, the factory building kit will boast three module types: process module, dose module and overflow module, which are to be offered in different heights. Module identification will take place using RFID interfaces.
- At last November's Formnext exhibition, the company showed a solution having a build envelope of 400 by 400 by >400 mm3, laser sources, process gas management and filter technology are integrated in the module, and layer thicknesses "are within the usual range".
