AM systems for metals: Innovations at Formnext 2024 targeting enhanced cost-effectiveness

Text: Thomas Masuch, 5 November 2024

Manufacturers of metal 3D printers are intensifying their focus on improving cost-effectiveness for industrial production. This trend will be showcased at Formnext 2024, with the innovations on display spanning everything from more efficient system operations to enhanced precision and automation. Additionally, the AM industry will demonstrate its ability to continue delivering entirely new technologies.

Bright Laser Technologies (BLT) will present the latest version of its metal laser powder bed fusion (LPBF) system, the BLT-S450. This model features a build volume of 400 mm × 450 mm × 500 mm (W × D × H) and a four-laser configuration. According to BLT, the new system offers several features that make it a game-changer in metal AM. These include cost efficiency, which it achieves by consuming very little argon. At the same time, the system is equipped with an automated powder circulation system that enables closed-loop powder recycling under inert gas protection.

The AconityX system from Aconity3D is designed for maximum flexibility. The system offers up to 6 x 4 kW laser power, flexible beam profiles, and interchangeable process chambers. In addition, AconityX features the new version of AconityStudio, as well as an Infinity Filter and Ultrafast Purging, which is designed to minimize set-up times and enable uninterrupted production.

Exciting innovations in hybrid machines

Visitors to Formnext 2024 will also be able to experience innovative developments in the field of hybrid machines. Multiax CNC, an Italian manufacturer of CNC machine tools, has joined forces with Rev3RD to develop a brand new project: a complete line of Cartesian 3D printers and a series of hybrid CNC machines that enable both 3D printing and milling. At Formnext both companies will showcase live in action a CNC machining center from the Multiax P-Series. This monolithic cell structure is designed for high performance, with a gantry driven by two motors ensuring optimal parallel movement. This reduces vibrations and achieves high precision, particularly in the high-speed machining of aluminum or composite materials.

DMG Mori will be showing off its new Lasertec 30 SLM 3rd Generation, whose design is entirely based on many years of experience in the construction of stable machine tools. The company has also completed the process chain in additive manufacturing with the DMU 60 eVo. Thanks to its PH Cell 300 pallet handling system, components printed on the powder bed are finished with a high degree of precision.

Applying metal powder with air pressure

With its new OmniFusion 3D system, Schaeffler is targeting the additive processing of metal multi-materials. The system is based on a “recoater”, which is essentially a sled that carries three rollers. These rollers are equipped with a fine grid structure onto which the material powder trickles from above. Since this takes place in a vacuum, the fine particles adhere to the rotating surface of the rollers.

Image: Schaeffler

The recoater then moves across the build platform at a speed of 15 cm/s and places the powder precisely where it is needed in the component. This is made possible by compressed air bars installed inside the rollers. Each of these bars is equipped with 832 tiny nozzles, which have a diameter of just 300 μm and create a powder landscape of 0.3 mm pixels.

Fully automated coating

Meanwhile, Prima Additive will present an exciting development which should be of particular interest to automotive specialists. Together with German automation specialists Comau, the Italian manufacturer of AM systems has developed a fully automated system for coating brake discs for Stellantis. By hard-coating raw brake discs with resistant steel and composite materials, Stellantis will be able to fully comply with the Euro 7 standard, which requires a 27% reduction in particulate emissions from brake discs by the end of 2026. The cells are also equipped with adjustable grippers that can handle windows of different sizes in cars and trucks. The system is due to be installed at the Septfonds plant in France by the end of 2024.

Image: Prima Additive

Stacking identical weld seams layer by layer

Fronius is set to unveil CMT Additive Pro, a 3D-optimized welding process that promises consistent layer buildup, high quality, and stability. In the new iWave Multiprocess Pro and the specially tailored CMT Additive Pro waveform for 3D metal printing, the company offers a high-performance welding system compatible with common robotic systems used in additive manufacturing.

Image: Fronius

Droplets now monitored in real time

At Formnext, Grob will present the next generation of its GMP300, which is based on liquid metal printing (LMP) and molten metal printing (MMP) technology. The GMP300 utilizes aluminum wire that is melted and printed onto a heated build plate measuring 300 x 300 mm, similar to an inkjet printer. According to Grob, this allows for a maximum build volume of 200 cm³ per hour. The new generation of the GMP300 features a variety of enhanced functions, including an improved sealing concept for the build chamber. A movable camera system monitors the droplets in real time, while a second camera system within the build chamber detects and reports any droplet misalignment.