Full speed ahead

There is a tide change in the market to turn rapid manufacturing into a technology that is mass market and low cost. Products such as upmarket lighting and furniture, dental implants, braces and false teeth, jewellery, and customised ear plugs and hearing aids are the starting point, as many of these are already benefiting from additive rather than subtractive production methods. Taking rapid manufacturing technologies to the wider market is the next trick. Many of the latest rapid manufacturing developments will be on view at the TCT 2010 exhibition taking place from 19-20 October at the Ricoh Arena in Coventry. One exhibitor, laser sintering specialist EOS (01926 623107), says that additive layer manufacturing applications are being extended continually by new EOS powders for laser sintering, using its EOSINT metal processing machines. Image: An aerospace part, courtesy of EOS' technology "Medical companies are already using our technology to create patient-specific medical products, tailored to an individual's anatomy and needs," says Martin Bullemer, key account manager medical at EOS, Germany. "As our quality and production controls continue evolving, designers and manufacturers will be able to achieve even more extraordinary advances in patient care and comfort." MEDICAL MATTERS EOS says that direct metal laser sintering (DMLS) systems are used currently for medical applications that include: stainless steel custom spinal surgical instruments; bespoke cobalt chrome replacement knee joints; end-product dental copings and bridges; and titanium dental implants with porous surfaces that promote osteointegration. Another TCT exhibitor, rapid product development company 3T RPD (01635 580284), is also becoming expert in medical applications, having recently been awarded the Dick Aubin Distinguished Paper Award, a much heralded US accolade presented by the Society of Manufacturing Engineers and the Rapid Technology and Additive Manufacturing Community. 3T RPD, along with co-author Jason Watson, a consultant at Nottingham University Hospitals Trust, identified an opportunity to use DMLS to produce cranial implants for patients who have parts of the skull removed following trauma or illness. The paper, titled 'DMLS – the future of custom-made cranioplasty design and manufacture', was recognised as providing an innovative application for this developing technology. Arcam (+46 31 710 3200) is another company harbouring significant interest in the medical sector, as demonstrated by the recent introduction of its Arcam A1 EBM (electron beam melting) system for the additive manufacturing of orthopaedic implants. The orthopaedic market is one of Arcam's two main targets – the company has more than 15 EBM production systems installed worldwide. According to US consulting firm Knowledge Enterprise, predicted annual global market growth in this area is approximately 10 per cent. Image: Arcam technology produced these acetabular cups Arcam has also enjoyed recent success in the aerospace sector, selling four EBM systems to Avio SpA of Turin. The machines are being used to manufacture titanium aluminide (TiAl) aero engine components. Titanium aluminide is an inter-metallic material that combines excellent mechanical properties at elevated temperatures with low weight – low weight in aero engine results in increased thrust-to-weight ratio, better fuel economy and lower emissions. Selective laser sintering/melting (SLS/SLM) is another rapid manufacturing process that will be prominent at TCT 2010. This technology uses a high power laser to fuse layers of fine metallic powders to form complex functional parts direct from the CAD model. Here, MTT (01785 815651) specialises in the delivery of such machines, which include the SLM125 and SLM250. Both feature innovations such as inert powder handling, safe change filter system and vacuum assisted inert atmosphere, and both are approved for use with titanium, stainless steel and cobalt chrome. Elsewhere at the show, Concept Laser's soon-to-be-launched M1Lab machine (available in the UK from ES Technology 01327 701107) is designed with smaller component sizes in mind, such as those for the jewellery and dental sectors. The M1Lab will provide the capability to build fully dense metallic parts in stainless steel, cobalt chrome and precious metals, with further new developments on the horizon. A big aspect of rapid manufacturing is 3D laser scanning, a technique used to collect data on component shape and appearance, which can be used to construct digital, 3D models useful for a variety of applications, such as industrial design, orthotics and prosthetics, reverse engineering and prototyping, and quality control/inspection. Suppliers of this technology, such as Faro (02476 217690), will use TCT to show its Faro Laser ScanArm, a contact/non-contact measurement system for inspection, point cloud-to-CAD comparison, rapid prototyping, reverse engineering and 3D modelling. Others, such as Europac Metrology (01270 216000), will exhibit a range of scanning and reverse engineering hardware and software that includes: a Cimcore portable measuring arm; Perceptron laser V4-V5 Scanworks (450,000 points/sec at 4.5 micron resolution); DS2 CNC white light and dental scanning, to an accuracy of 10 micron; and 3D solid modelling from scan data with live transfer into CAD. The theme of new 3D scanning technology will continue on the stand of Nikon Metrology (01332 811349), where the company's ModelMaker MMDx series with digital ESP3 technology can be seen. MMDx now scans nearly all materials and surface finishes by automatically using the optimum laser stripe settings. Through ESP3 technology, MMDx digitises surfaces with varying colour or abrupt surface finish transitions under any lighting conditions by adapting laser beam intensity point per point. Image: Faro's Laser ScanArm, a contact/non-contact measurement system for inspection, point cloud-to-CAD comparison, rapid prototyping, reverse engineering and 3D modelling Visitors to the stand of Measurement Solutions (01733 325252) will be able to see live demonstrations of the latest Handyscan3D and Kreon laser scanning solutions. Here, a particular focus of attention will be the ease of use and the ability to inspect and reverse engineer to a high resolution and accuracy – everything from small components to a complete car. Similarly, Central Scanning (01527 558282) will be exhibiting the latest Steinbichler and ARTEC 3D scanning products, while mobile laser scanning will be the theme on the Wenzel (01452 728298) stand, via its MobileScan3d solution. With three interchangeable scanning heads and rotary table, MobileScan3d supports reverse engineering or inspection to CAD. Increasing numbers of metrology equipment suppliers are moving into the scanning field. Carl Zeiss (01788 821770), an established specialist in co-ordinate measurement, now has a product range that extends to CT scanning and optical metrology. At TCT, Carl Zeiss will be showing its DuraMax CMM and presenting its contract measurement facility, which encompasses dimensional measurement and CT scanning. For visitors interested in scanning large objects, the new Quartz scanners from Phase Vision (01509 839000) are sure to be of interest. Originally developed for demanding conditions in the aerospace sector, Phase Vision pioneered the development of white light 3D scanners for the shopfloor, aircraft hangar or dockyard. The Quartz range is being launched after months of testing in these tough environments, bringing several advantages, such as the measurement of large objects and the 360° measurement of complex objects, at production line speeds. MULTI-SENSOR TECHNOLOGY New exhibits on the stand of Hexagon Metrology (0870 446 2667) include the Optiv range of vision and multi-sensor measuring systems. Optiv supports multi-sensor measurements using video sensors, tactile sensors, through-the-lens (TTL) lasers, as well as chromatic white light (CWS) sensors. Hexagon will also show its recently introduced new generation of ROMER portable 3D measuring arms. The ROMER Absolute Arm is the first measuring arm to have absolute encoders, a development that will greatly simplify the inspection process, says Hexagon. Coming at things from a different angle, Delcam says it will demonstrate how high speed programming with its FeatureCAM software can make machining of components faster than rapid manufacturing. Delcam will also support three of the main themes for the associated conference by featuring its latest software for the metrology, dental and jewellery industries. FeatureCAM uses feature-based and knowledge-based technology to allow programming of machining programs in seconds. The software's automatic feature recognition capability first identifies the machining features of the part and then automatically selects the tooling, machining strategies, and speeds and feeds to machine each feature efficiently. The selection can be made using the built-in machining knowledge that Delcam supplies 'out of the box' within FeatureCAM, or from experience captured from the company's or individual user's manufacturing preferences. The new release incorporates automatic surface inspection and the ability to use GD&T data from CATIA models, plus improvements to the handling of point cloud data and changes to the interface to make the software even easier to use. Another CADCAM developer at the show with a new product offering is Tebis (02476 236413). Tebis V3.5 features highly automated NC programming and improved process safety, as well as increased speed and greater reliability. Handling STL files is, of course, not without its issues. But help is at hand for visitors to TCT, where Materialise (01142 541249) will release enhanced free software for STL inspection and compression. MiniMagics 2 is a tool for anyone that would like to view or interact with an STL file. Its enhanced measurement options offer increased flexibility and enable accurate measurements to be taken using points, lines, circles and planes, while for instant geometry appreciation, view options now include shade, wireframe, shade and wire, triangle and transparent. Similarly, Netfabb (+49 9492 601 6400) will be offering 'Cloud Services', the company's next free product for the world of additive manufacturing. With Netfabb Cloud Services, it is possible to analyse, check and repair STL files automatically, for free. It can be used from any web browser, running on any platform and any operating system. Box item 1 Rapid manufacturing facility has teeth Renishaw has opened a new facility that will allow the manufacture of low-cost CADCAM frameworks using pure, certified medical-grade cobalt chrome. The new copings and frameworks will be produced using DMLS and will allow dental laboratories to offer a high quality, lower cost alternative to ceramic restorations, which Renishaw is calling Laser PFM. "The DMLS process is much cleaner and more efficient than traditional investment ('lost wax') casting techniques used for many years to produce metal frameworks, and we believe that our new service will appeal to laboratories technicians who would like to remove a messy process and free up space," says Bryan Austin, director of Renishaw's Dental Products Division. "With so much concern about imported metal crowns, it will also be reassuring that the new cobalt chrome copings and frameworks are from a certified source, and are free from nickel, beryllium and cadmium. All customers are welcome to visit the facility." Image: Renishaw has opened a new facility that will allow the manufacture of low-cost CADCAM dental frameworks