A brand new system is pushing the boundaries of what’s attainable in depowdering for metallic 3D printing, tackling elements that weigh over two tons and have intricate designs. Unveiled at Formnext 2024, the SFM-AT1500-S, developed by Solukon, is able to dealing with components as much as 2,100 kg (roughly 4,630 kilos), addressing the challenges of cleansing a number of the largest and most advanced 3D printed metallic elements. Now, Solukon has introduced AMCM as one of many first clients for this groundbreaking machine.
The SFM-AT1500-S can accommodate a part equivalent to this copper rocket engine within the center. Picture courtesy of Solukon.
Solukon says the machine is designed to deal with difficult inside powder elimination and match into tight areas in manufacturing websites. Its compact construct means no exterior platforms or stairs for loading are wanted, making it simpler to make use of in smaller amenities whereas coping with the challenges of cleansing advanced constructions.
Created to deal with extra-large and heavy 3D printed metallic elements, this technique guarantees to accommodate components as much as 600 x 600 x 1,500 mm or 820 x 820 x 1,300 mm in measurement.
AMCM, a machine producer and subsidiary of EOS primarily based in Starnberg, Germany, labored intently with Solukon to assist design the SFM-AT1500-S depowdering system. AMCM wanted the system to deal with components made by its M 8K printer, which might produce extra-large elements as much as 820 x 820 x 1,200 mm. With a construct quantity 4 occasions bigger than its predecessor, the M 4K, and the power to deal with as much as 5 tons of powder, the M 8K incorporates EOS’s expertise to enhance high quality assurance and course of monitoring.
In truth, this M 8K was developed with a nationwide grant to help ArianeGroup’s Ariane 6 program. It was particularly created to 3D print massive and sophisticated components like rocket engine combustion chambers for ArianeGroup’s Prometheus rocket engine—an ongoing European House Company (ESA) improvement effort begun in 2017 to create a reusable methane-fueled rocket engine. Now, by collaborating with Solukon, AMCM ensured that the depowdering system would meet the demanding necessities of cleansing these large and complicated elements.
Described as an ideal match for AMCM’s M 8K machine, the SFM-AT1500-S depowdering system is predicted to streamline the post-processing of ArianeGroup’s Prometheus rocket engine. Whereas AMCM is scheduled to ship its first 3D printed combustion chambers in copper alloy, the corporate has prior expertise producing comparable elements. Utilizing its M 4K system, AMCM efficiently manufactured combustion chambers and injectors for liquid rocket engines that includes intricate regenerative cooling channels.
One of many key options of the SFM-AT1500-S is its proprietary SPR-Pathfinder software program, which simplifies the depowdering course of. The software program reads the CAD file of an element and calculates one of the simplest ways to take away leftover powder, so there’s no want for guide programming. This automated method saves time, lowers prices, and minimizes errors, ensuring even essentially the most advanced inside constructions are completely cleaned.
“SPR-Pathfinder is a device that each buyer will surely wish to have, and so will we. The software program is indispensable for advanced elements as a result of the precise motion sample for very advanced geometries can’t be generated utilizing human creativeness alone. The software program eliminates the necessity for any human programming effort,” says Martin Bullemer, Managing Director of AMCM.
Whereas conventional depowdering strategies may be time-consuming and will not successfully take away powder from advanced geometries, SFM-AT1500-S addresses these challenges. Conventional strategies typically battle with intricate inside designs, like lattice constructions or slender channels, the place powder will get trapped. Elements like static electrical energy, floor roughness, and even compaction throughout printing make it tougher to clear residual powder.
For instance, within the aerospace business, turbine blades or warmth exchangers typically embrace fantastic inside channels for airflow. If leftover powder stays trapped, it could actually block airflow or weaken the half below stress, compromising the structural integrity below intense vibration and G-forces, ultimately resulting in a possible half failure. Equally, in medical functions, residual powder trapped within the porous constructions of implants designed to advertise bone development could cause contamination or scale back the implant’s efficiency.
As an alternative, by automating this course of and accommodating bigger elements, Solukon’s new system ensures manufacturing effectivity and product reliability.
Except for aerospace and medication, this machine may also be utilized in different industries like protection and transportation, the place large-scale metallic components are frequent. What’s extra, this potential to scrub bigger elements opens new prospects for designing and manufacturing extra advanced and environment friendly constructions that have been beforehand unattainable.
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