By Cassandra Balentine
The use of three-dimensional (3D) printing is continuously advancing for use in the automotive industry. Our June issue discusses the latest advancements for metal additive manufacturing (AM) as it relates to automobile parts and production.
Here we round up vendor products that serve this space.
Additive Industries
Additive Industries has designed a modular, scalable and automated machine platform—the MetalFAB G2, which is available in multiple configurations starting the Core System and advancing to Serial Production. Wherever a business is in the adoption cycle of metal 3D printing there is a configuration that will suit its needs.
By attaining higher overall equipment effectiveness through integrated automation, Andrew Hawkins, product marketing manager, Additive Industries, says the MetalFAB G2 range of 3D printing systems offer our customers unrivaled flexibility, with various options and configurations available based on their requirements and maturity.
Traditional industrial 3D printing technologies come with several constraints including low productivity and reliability due to lack of automation and printer robustness, inadequate level of metal powder handling, posing safety concerns and inconsistent quality and inefficiency due to calibration issues.
The MetalFABG2 range overcomes these barriers to adoption in serial production with a range of innovative technologies and also allows a great degree of flexibility due to the modular design, where the system can be re-configured quickly and easily in the field as production requirements change.
GEFERTEC
GEFERTEC was the first company to utilize the proven arc process for industrial 3D metal printing, Wire Arc Additive Manufacturing (WAAM). Its machine is designed as a complete production system based upon the WAAM. According to Sebastian Recke, senior key account manager, GEFERTEC GmbH, the process scores highly in the production of large components, currently up to eight cubic meters. WAAM offers high build rates and is around ten to 20 times higher than laser powder bed fusion. Because wire is used as the raw material, handling is easy and the material is cost effective.
The machine’s kinematic uses a CNC-controlled linear axis system whose high precision ensures sustained process stability and repeatability throughout the entire workspace. “The system has already proven this in series production, e.g. at Siemens Energy in three-shift operation,” comments Recke.
Traditional metal inert gas welding is used for the AM of parts. The arc machines combine this with special CAM software and a Sinumerik control architecture. “The machines are already being used extensively in industrial applications, such as series production of turbine components in the energy sector. This year GEFERTEC introduces the next generation of its arc machines, the arc80X,” notes Recke.
In the three-axis version, Recke explains that the new production system has a workspace of 2x2x2 meters and can produce parts with a total mass of up to eight tons. The five-axis version prints parts with a diameter of up to 0.9 meters and a height of up to 1.4 meters. In addition to the larger workspace, this new generation of machines offers many other advantages. These include a higher degree of automation to improve production efficiency and reduce personnel requirements. Automated functions include integrated tool measurement, gas nozzle cleaning, wire cutting, and replacement of certain wear parts.
A comprehensive process monitoring ensures part quality. The process monitor records and stores all relevant data during the printing process. “This allows comprehensive documentation for quality assurance and process optimization. An integrated pyrometer measures the part temperature and, together with active component cooling, contributes to optimal quality of the printed part. The optional inert gas box enables printing in a closed inert gas atmosphere. This allows the unit to process even sensitive materials such as titanium,” shares Recke.
Recke feels that many potential users of the innovative 3D printing process are reluctant to invest in their own machines, often due to a lack of expertise within the company. For those companies GEFERTEC offers a comprehensive service package. With its extensive know-how, GEFERTEC process technicians and CAM engineers support customers in easily changing over their parts manufacturing process to the arc machines. Services include parts screening to review technical feasibility and to identify potential areas of increased efficiency. “GEFERTEC experts can also help in the qualification of process parameters and the planning of the tool path via CAM software. This allows customers to make optimal use of the arc machine and start 3D printing with WAAM—even without in-house experts.”
Fabrisonic LLC
With the rise of electric vehicles, Mark Norfolk, president, Fabrisonic LLC feels that 3D printing plays a significant role in producing components for battery packs, electric motors, and other EV-specific parts. “The flexibility of AM allows for innovative designs optimized for electric propulsion systems.”
Fabrisonic solid state Ultrasonic Additive Manufacturing (UAM) is uniquely suited to three components, UAM feedstock is thin metal foils, already a prime input of electrical parts. UAM does not melt metal. “In fact welds in aluminums and copper happen near room temperature,” shares Mark Norfolk, president, Fabrisonic LLC.
He says this allows printing directly adjacent to sensitive electronics without worry of damage. “With proper automation, UAM can be used at high volumes. One customer printed approximately 35 million automotive components in 2023 using UAM.”
In terms of consumables, Fabrisonic provides metal foil stock to customers, if needed. “The nice thing about metal foils is they can be bought for most engineering metals to existing AMS specifications. Standard alloys of aluminum (6061, 7075, 2024, 1100), copper (110, 101), stainless (304, 316), Inconel (600, 625), and even tantalum are commercially available in foil form as a commodity,” says Norfolk.
HP Inc.
In September 2022, HP introduced its most advanced 3D printing technology for metals, the HP Metal Jet S100 Printing solution. The full value chain approach allows customers to scale economically and address end-to-end needs both in software and in hardware.
“Since introducing the HP Metal Jet S100 Solution, the demand for and availability of 3D metals has rapidly expanded. In order to meet increased demand for this technology and achieve the long-standing goal of delivering the best-in-class metals offerings for customers, HP has been focused on enhancing 3D metal software capabilities to help customers develop metals applications more quickly and easily than ever before in a new era marked by digitized manufacturing,” says Alexandre Tartas, global head of 3D metals go-to-market, HP Personalization and 3D Printing.
For example, HP’s 3D Digital Sintering software tool utilizes artificial intelligence and physics-based modeling to predict, report, and compensate for variability of Metal Jet parts during sintering such as shrinkage and deformation. This eliminates the need for a build and test approach, speeding up production workflow for application engineers.
“When used in conjunction with the HP 3D Process Development tool, Metal Jet S100 customers can further optimize their printing procedure. The software provides customers with insight into HP’s 3D printing technology, opening up process parameters and enabling customers to do guided experimentation so they can develop their own production processes and optimize their 3D printed metal applications. Once a production process is established, users apply the same software to fleets of HP Metal Jet S100 printers, expanding the capabilities of their 3D production systems to drive more rapid and agile product development and end-to-end solutions,” notes Tartas.
The HP Metal Jet S100 Solution is an open materials platform. “We offer metal powder that is co-branded with powder material suppliers or users can source their own powder with the guidance of HP,” says Tartas.
Advancing productivity and quality is a focal point for HP’s service to its Metal Jet customers, which is why HP announced several strategic collaborations last fall with GKN Additive (Forecast 3D) and Sandvik to offer unique material offerings that revolutionize manufacturing processes and products.
The GKN collaboration encompasses the introductory qualification of a diverse range of materials for HP’s Metal Jet S100 customers, including ten different steel grades such as M2 tool steel and a dual-phase steel (Free Sintering Low Alloy) capable of taking tooling to the next level. The Sandvik partnership gives HP Metal Jet customers access to superalloys and high performing, competitively priced 316L, enabling the development of innovative applications across various industries, including automotive.
AM for Automotive
3D printing plays an increasingly important role in automobile manufacturing. The technology continues to evolve as illustrated by these vendors.
Jun2024, Industrial Print Magazine
