Ebm 5-6 PDF

Arcam EBM system
Rapid Manufacturing
with
Electron Beam Melting (EBM )
2006-12-06
Free Form Fabrication machines for Direct Manufacturing
Arcam EBM system
Outline
2006-12-06
Overview
EBM S12 System
Applications
Materials
Arcam EBM system
CAD to Metal
LayerLayer-based Direct Manufacturing of complex parts by

melting metal powder with Electron Beam Melting (EBM)
A revolution in the Art of Manufacturing!
2006-12-06
Arcam EBM system
Arcam in short
2006-12-06
Swedish innovation from the beginning of 1990s

Arcam AB incorporated 1997
Listed on Nordic Growth Market, Stockholm Stock Exchange
Solid Owners - Industrial Development Trust + large private
investors
Beta machines to the market in 2002
First EBM S12 machine delivered March 2003
>25 installations worldwide
26 employees, 2 in the US
Agents in Europe, Asia and the US
Arcam EBM system
Arcam Products & Services
Machines and Equipment for

Electron Beam Melting
Service and Application Support
Powder Metals and Consumables
2006-12-06
Arcam EBM system
Applications
Aerospace
Medical
Implants
Prosthesis
Instruments
Prototypes
Automotive
2006-12-06
Functional Parts
Prototypes
Functional Parts
Prototypes
Arcam EBM system
Clients
Examples of clients include
End Users
Boeing Phantom Works, St Louis, USA
NASA, Marshall Space Flight Center, USA
Airbus, Bristol, UK
Unnamed Implant Manufacturers, Asia / Europe / USA
Service Bureaus
CalRAM, USA
Synergeering Group, USA, 2 systems
Protocast, Italy
Fruth Innovative Technologien, Germany
Research Institutes
North Carolina State University, USA
Erlangen University, Germany
Royal College of Art, London, UK
2006-12-06
Arcam EBM system
Materials
100% Density
Normal properties for:

Strength & Elasticity
Hardness
Chemical composition
Thermal properties
2006-12-06
Qualified
Ti6Al4V
Ti6Al4V ELI
Commercially Pure, Grade 2
CoCr,
CoCr, ASTM F75
R&D
Inconell 718, 625
Beryllium/AlBeMet
Beryllium/AlBeMet
GRCopGRCop-84
Stainless Steels - 316L, 1717-4PH
Aluminium Alloys
Arcam EBM system
Process overview
1. CAD-model
2. EBM
3. Metal Part
The part is designed in a 3D CAD

program or created from a CT-scan of
The part is built up by melting

metal powder layer-by-layer with
the Arcam Electron Beam Melting
(EBM) process.
The result is a
functional metal part, ready to
be put into operation!
a patient. The CAD-file is saved as an

STL file which is used to prepare the
job.
The STL-file is sliced into an SLC-file
and transferred to the Arcam EBM
system
2006-12-06
Arcam EBM system
Electron Beam Melting (EBM)
Electrons are emitted from

a filament which is heated to
> 2500 C
The electrons are accelerated
through the anode
A magnetic field lens brings the
beam into focus
Another magnetic field controls
the deflection of the beam
When the electrons hit the
powder kinetic energy is
transformed to heat.
heat.
The heat melts the metal
powder
Power is controlled by altering
the current in the beam.
No moving parts!
2006-12-06
10
Arcam EBM system
EBM Characteristics
2006-12-06
Ability to achieve high power (4 kW available) in a narrow beam.

High power utilization
High build temperature
Beam Deflection with no moving parts
Vacuum melt quality eliminates impurities and yields high strength
properties of the material.
Good thermal environment, leading to good form stability and low
residual stress in the part
Permits melting of refractory metals and combinations of dissimilar
metals
Low operating costs
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Arcam EBM system
Core benefits
Full functionality of parts

Fully melted material - 100% density
Better than cast
Controlled grain size
High strength
Fast & Economical Fabrication

High Build Rate
Power Efficiency
Material Recycling
2006-12-06
12
Arcam EBM system
Outline
Overview
EBM S12 System
Applications
Materials
2006-12-06
13
Arcam EBM system
Arcam EBM S12

Electron Beam Gun
with Focus and
Deflection System
Touch
Screen
Monitor
Inspection Window
Control
Unit
Vacuum Chamber with

Building Table, Powder
Containers and Powder
Distributor
High Voltage
Supply
2006-12-06
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Arcam EBM system
Arcam EBM S12 Technical Data

Building tank volume
250 x 250 x 200 mm
Maximum build size
200 x 200 x 180 mm
Accuracy
+/- 0.4 mm
Melting speed
0.3-0.5 m/s
Layer thickness
0.050- 0.200 mm
EB scan speed
> 1000 m/s
EB positioning accuracy
+/- 0.05 mm
Max EB output
4 kW
Power supply
3 x 400 V, 32 A, 7 kW
Machine size
Approx. 1800 x 900 x 2200 mm
Weight
1350 kg
Process computer
PC / XP Professional
CAD interface
Network
Certification
Standard: STL
Ethernet 10/100
CE
2006-12-06
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Arcam EBM system
User interface
Inspection window for
optical observation of object
Touch Screen
Monitor
Menu based control system

with video monitoring of
build process
Keyboard
2006-12-06
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Arcam EBM system
Powder Recycling System
2006-12-06
> 95% powder recycling

Minimal dust generation for
safe operation
Closed circuit until powder
recycling is completed
Good accessability and
efficient sideloading
17
Arcam EBM system
Invisible Supports
2006-12-06
Soft supports developed for easy removal after build

Partially sintered, 100% rere-usable powder
Easily removed by hand
Enables stacked builds
18
Arcam EBM system
Outline
2006-12-06
Overview
EBM S12 System
Applications
Aerospace
Medical
Automotive
Miscellaneous
Materials
19
Arcam EBM system
Landing Gear Component

Material: Ti6Al4V
Weight: 4,5 kg
2006-12-06
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10
Arcam EBM system
Aerospace Prototype
Material:
Weight:
2006-12-06
Ti6Al4V
5,5 kg
21
Arcam EBM system
Rocket Engine Impeller

Material: Ti6Al4V ELI
Size:
140 x 80 mm
Weight: 2,5 kg
Picture courtesy of CalRam, Inc.
2006-12-06
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11
Arcam EBM system
CLV Interstage End Fitting
CLV Interstage End Fitting Ti-6Al-4V
POC: Jeff Finckenor, MSFC/EV32
Manufactured by Synergeering for NASA Marshall Space Flight Center

2006-12-06
23
Arcam EBM system
Outline
2006-12-06
Overview
EBM S12 System
Applications
Aerospace
Medical
Automotive
Miscellaneous
Materials
24
12
Arcam EBM system
Direct Implant Manufacturing

Specific benefits for Implants and Prosthetics
Short and easy transition from CT or MRI data
- to CAD model to part!
No tools, part design can be individualized
Moderate production lots without setting times
Possibility for engineered materials, porosity, scaffolds
CAD to Metal is often quicker and less costly than conventional
methods
2006-12-06
25
Arcam EBM system
Customized TriTri-flange Implant

Material:
Build time:
2006-12-06
Ti6Al4V
4 hours
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13
Arcam EBM system
Parts direct from CTCT-scan
Material:
Size:
Weight:
Build time:
2006-12-06
Ti6Al4V
225 x 160 x 170 mm
ca 2,5 kg
24 hours
27
Arcam EBM system
Customized Bone Plate

Material:
Size:
Weight:
Build time:
2006-12-06
Ti6Al4V
5 x 20 x 55 mm
3 hours / 6 pieces
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14
Arcam EBM system
Controlled Porosity
The material can incorporate Controlled Porosity and

scaffolds.
This enables design for bone ingrowth and reduces the
number of process steps in manufacturing.
Pictures of bone growing into titanium implants with

controlled porosity, manufactured in the EBM process.
(courtesy of Professor Peter Thomsen, MD,
Dept. of Biomaterials, University of Gothenburg).
2006-12-06
29
Arcam EBM system
Advanced Gratings
2006-12-06
The process supports production of Advanced Gratings and

Engineered Materials. Possibilities include:
Scaffolds
Light weight design
Mass production of tiny structures, e.g. Spine tubes
Bone ingrowth
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15
Arcam EBM system
Lattice Structures
Material:
Size:
Build time:
2006-12-06
Ti6Al4V
25 x 65 x 180 mm
6 hours
31
Arcam EBM system
Acetabular Cups
Material:
Ti6Al4V
With fully dense core.

Outer surface either fully dense, with
low porosity or with high porosity
Low porosity
High porosity
2006-12-06
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16
Arcam EBM system
Direct Implant Manufacturing, costs
Competitive manufacturing cost, typical cost 110 EUR per

machine hour, including operator, powder and financial costs.
One typical build overnight gives, for example;

6 hip implants @ 200 EUR per part
9 acetabular cups @ 120 EUR per part
4 tri-flange @ 300 EUR per part
50 moderate size bone plates @ 30 EUR per part
4 complex bone plates @ 400 EUR per part
2006-12-06
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Arcam EBM system
Outline
2006-12-06
Overview
EBM S12 System
Applications
Aerospace
Medical
Automotive
Miscellaneous
Materials
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17
Arcam EBM system
Race Car Gearbox Casing

Material:
Weight:
2006-12-06
Ti6Al4V
2,5 kg
35
Arcam EBM system
Race Car Suspension Parts

Material:
Size:
Weight:
2006-12-06
Ti6Al4V
160 x 210 x 105 mm
1130 grams
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Arcam EBM system
Race Car Suspension Parts

Material:
Size:
Weight:
Build time:
2006-12-06
Ti6Al4V
60 x 20 x 80 mm
90 grams
4.5 hours / 6 pieces
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Arcam EBM system
Spine Model for Crash Tests

Material: Ti6Al4V
All components packed into one
build.
2006-12-06
38
19
Arcam EBM system
Outline
2006-12-06
Overview
EBM S12 System
Applications
Aerospace
Medical
Automotive
Miscellaneous
Materials
39
Arcam EBM system
Sports Technology
Direct Manufacturing of Ice Axe Blade in CoCr alloy.
2006-12-06
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Arcam EBM system
Impeller Prototype
Material:
Size:
Build time:
2006-12-06
Ti6Al4V
120 x 30 mm
8 hours
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Arcam EBM system
Outline
2006-12-06
Overview
EBM S12 System
Applications
Materials
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21
Arcam EBM system
Material Development
2006-12-06
Material Properties are essential

for demanding applications.
Arcam R&D is committed to
ensure first-class mechanical
properties on all qualified
materials.
All qualified materials are
extensively tested before
release to customers.
43
Arcam EBM system
Chemical Composition
2006-12-06
Pre-alloyed metal powder

No additives or binders
Retained chemical composition due to:
Good vacuum <10-4 mbar
Very small melt volume
Rapid cooling from liquid to solid state
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22
Arcam EBM system
Arcam Ti6Al4V
Arcam Ti6Al4V Titanium Alloy has a homogenous finefine-grain microstructure better

than cast Ti6Al4V containing a lamellar alphaalpha-phase with larger betabeta-grains. The
material comes out of the Electron Beam Melting process in a naturally aged
condition.
2006-12-06
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Arcam EBM system
Arcam Ti6Al4V
The most widely used Titanium Alloy

Mechanical properties:
Yield strength (Rp
(Rp 0,2)
Ultimate tensile strength (Rm
(Rm))
Rockwell hardness
Elongation
Fatigue strength*) @ 66-600 MPa
Modulus of Elasticity
910910-960 MPa
970970-1030 MPa
3030-35 HRC
1212-16%
>10 million cycles
120 GPa
*) After Hot Isostatic Pressing
2006-12-06
Applications:
High performance parts
Aerospace
Racing
Implants
Marine
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23
Arcam EBM system
Arcam Ti6Al4V ELI
Extra Low Interstitials (ELI)

Yield strength (Rp
(Rp 0,2)
(Rm))
Rockwell hardness
Elongation
Fatigue strength*) @ 66-600 MPa
Modulus of Elasticity
910910-940 MPa
950950-990 MPa
3030-35 HRC
1414-16%
>10 million cycles
120 GPa
*) After Hot Isostatic Pressing
2006-12-06
Applications:
Implants
Aerospace
Cryogenic applications
47
Arcam EBM system
Fatigue/Endurance
2006-12-06
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24
Arcam EBM system
Arcam ASTM F75 Cobalt Chrome Alloy
Medium strength and stiffness

High Corrosion Resistance
Yield strength (Rp
(Rp 0,2)
(Rm))
Rockwell hardness
Elongation
Applications:
Orthopaedic Implants
Prosthesis
Aerospace
2006-12-06
600 MPa
900 MPa
34 HRC
10%
49
Arcam EBM system
Specialty materials GRCopGRCop-84
High Temperature Copper Alloy, CuCu-8at.%Cr8at.%Cr-4at.%Nb

4at.%Nb
Originally developed by NASA for rocket engines
GRCopGRCop-84 is rapidly finding applications within aerospace,
motor sports and industrial applications.
Material features:
high relative strength
potential for high heat flux applications up to 700 C
excellent elevated temperature strength
excellent thermal conductivity
good creep resistance
2006-12-06
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25
Arcam EBM system
Contact
Thank you for your attention!

Arcam AB
Kroksltts Fabriker 30
SE-431 37 Mlndal, Sweden
Phone: +46 31 710 32 00
Web site: http://www.arcam.com
E-mail: info@arcam.com
Use Arcam to manufacture your future!
2006-12-06
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Arcam EBM system

Electron Beam Melting (EBM )

Free Form Fabrication machines for Direct Manufacturing

Arcam EBM system

Free Form Fabrication machines for Direct Manufacturing

Arcam EBM system

LayerLayer-based Direct Manufacturing of complex parts by

A revolution in the Art of Manufacturing!

Free Form Fabrication machines for Direct Manufacturing

Arcam EBM system

Swedish innovation from the beginning of 1990s

Free Form Fabrication machines for Direct Manufacturing

Arcam EBM system

Arcam Products & Services

Machines and Equipment for

Service and Application Support

Powder Metals and Consumables

Free Form Fabrication machines for Direct Manufacturing

Arcam EBM system

Free Form Fabrication machines for Direct Manufacturing

Arcam EBM system

Free Form Fabrication machines for Direct Manufacturing

Arcam EBM system

Normal properties for:

Free Form Fabrication machines for Direct Manufacturing

Arcam EBM system

The part is designed in a 3D CAD

The part is built up by melting

a patient. The CAD-file is saved as an

Free Form Fabrication machines for Direct Manufacturing

Arcam EBM system

Electron Beam Melting (EBM)

Electrons are emitted from

Free Form Fabrication machines for Direct Manufacturing

Arcam EBM system

Ability to achieve high power (4 kW available) in a narrow beam.

Free Form Fabrication machines for Direct Manufacturing

Arcam EBM system

Full functionality of parts

Fast & Economical Fabrication

Free Form Fabrication machines for Direct Manufacturing

Arcam EBM system

Free Form Fabrication machines for Direct Manufacturing

Arcam EBM system

Arcam EBM S12

Vacuum Chamber with

Free Form Fabrication machines for Direct Manufacturing

Arcam EBM system

Arcam EBM S12 Technical Data

250 x 250 x 200 mm

Maximum build size

200 x 200 x 180 mm

> 1000 m/s

Approx. 1800 x 900 x 2200 mm

Free Form Fabrication machines for Direct Manufacturing

Arcam EBM system

Menu based control system

Free Form Fabrication machines for Direct Manufacturing

Arcam EBM system

Powder Recycling System

> 95% powder recycling

Free Form Fabrication machines for Direct Manufacturing

Arcam EBM system