Metal AM Autumn 2019 SP

Vol. 5 No.
3 AUTUMN 2019 THE MAGAZINE FOR THE METAL ADDITIVE MANUFACTURING INDUSTRY
METAL
AM
in this issue
SINTAVIA SET FOR GROWTH
BINDER JETTING & FFF: SINTERING FOCUS
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MANUFACTURING
Managing Director, Features Editor
Nick Williams
nick@inovar-communications.com
Publishing Director, News Editor

Paul Whittaker
Taking a more nuanced approach

paul@inovar-communications.com
Deputy Editor
Emily-Jo Hopson
emily-jo@inovar-communications.com
to the Gartner Hype Cycle
Assistant Editor
Kim Hayes Until recently it was hard to avoid an AM conference presentation
kim@inovar-communications.com that mentioned the Gartner Hype Cycle and the infamous Slope of
Production Manager Enlightenment. Where were we on the cycle, and had we passed
Hugo Ribeiro
the Peak of Inflated Expectations? As it became clear that the
hugo@inovar-communications.com
industry was achieving sustained growth, discussions around this
Advertising died down.
Jon Craxford, Advertising Sales Director
Tel: +44 (0)207 1939 749
However, because Laser Powder Bed Fusion (L-PBF) has
Fax: +44 (0)1743 469909
jon@inovar-communications.com dominated the metal AM scene over the past decade, it could
be argued that metal AM’s current place on the Slope of
Subscriptions
Metal Additive Manufacturing is published on a
Enlightenment is actually only L-PBF’s place. After all, more
quarterly basis as either a free digital publication than any other AM process, it has been through an intense period
or via a paid print subscription. The annual print of industrialisation, driven by advances in quality monitoring
subscription charge for four issues is £95.00 systems, standards, simulation technologies and materials.
including shipping. Rates in € and US$ are
available on application.
Whilst it is logical to bundle all metal AM processes together
Accuracy of contents to describe an industry, in doing so there is a danger of
Whilst every effort has been made to ensure the
accuracy of the information in this publication, misrepresenting the technological readiness of all the processes
the publisher accepts no responsibility for that fall within it.
errors or omissions or for any consequences
arising there from. Inovar Communications Ltd The rise of metal Binder Jetting is a case in point. It is a hugely
cannot be held responsible for views or claims
exciting technology, but with a unique supply chain. On one side,
expressed by contributors or advertisers, which
are not necessarily those of the publisher. there are established players with proven technologies that have
evolved out of low-volume production needs. On the other, there
Advertisements
Although all advertising material is expected are new entrants with hundreds of millions of development dollars
to conform to ethical standards, inclusion in behind them aimed at high-volume production, but with yet to be
this publication does not constitute a guarantee proven technology. Logically, correctly placing this process on the
or endorsement of the quality or value of
Hype Cycle requires caution.
such product or of the claims made by its
manufacturer.
To help to moderate inflated expectations, avoid troughs of
Reproduction, storage and usage
disillusionment and offer some enlightenment, this issue focuses
Single photocopies of articles may be made
for personal use in accordance with national on the elephant in the Binder Jetting room – the sintering process.
copyright laws. All rights reserved. Except as As we reveal, it is not a dark art, but there is no ‘easy button’
outlined above, no part of this publication may either and, just as we have seen with L-PBF, a lot of factors will
be reproduced, modified or extracted in any form
have to come together for this technology to reach the Slope of
or by any means without prior permission of the
publisher and copyright owner. Enlightenment.
Printed by
Nick Williams
Cambrian Printers, Aberystwyth, UK
Managing Director
ISSN 2057-3014 (print edition)
ISSN 2055-7183 (digital edition)
Vol. 5 No. 3 Autumn/Fall 2019 Cover image
EOS M400 systems installed at
This magazine is also available for free Sintavia LLC for the production
download from www.metal-am.com of components for the
© 2019 Inovar Communications Ltd aerospace and defence sector
Metal Additive Manufacturing | Autumn/Fall 2019 3

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Autumn/Fall 2019 METAL
ADDITIVE
MANUFACTURING
72 80 121 127 171
Contents
117 Sintavia: New facility signals the move Nick Williams interviews Stefan Joens and the
towards volume metal AM for aerospace team at Elnik Systems LLC, a leading provider
and defence of industrial debinding and sintering furnaces,
about the reality of entering this field and the
In May 2019, Sintavia, LLC opened a state-of-the-art
technologies and equipment that are needed for
facility in Hollywood, Florida, USA, dedicated to the
the often underestimated processes of debinding
volume production of metal AM components for the
and sintering.
aerospace and defence sector, marking a significant
expansion of the company’s production capacity.
Debbie Sniderman visited the new facility on behalf 151 Velo3D: How a ‘support-free’ Laser
of Metal AM magazine and reports on the company’s Powder Bed Fusion process could
ambitious plans and its management’s views on the remove roadblocks to serial AM
ongoing evolution of the industry.
159 New horizons for AM in the oil, gas and
127 Thinking about metal Binder Jetting or maritime industries
FFF? Here is (almost) everything you need
to know about sintering 169 Redesigned for AM: Serial production
With the arrival of high-volume metal Binder Jet of a new fuel swirler for Siemens gas
systems and a growing interest in metal Fused turbines
Filament Fabrication, the AM industry is set for a
new phase of growth. The ability to use this new 175 Understanding metal powder
generation of systems for the production of ‘green’ requirements for AM: Views from the
parts is, however, only half of the story. As Prof industry
Randall German explains, the thermal processing
of these parts to create large quantities of finished 185 Towards a true digital twin for the metal
product to a consistent quality requires a thorough Additive Manufacturing process
understanding of the sintering process and its core
Regular features
challenges.
141 Binder Jetting and FFF: Considerations

when planning a debinding and sintering
facility for volume production 7 Industry news
A new generation of Binder Jetting machines 192 Events guide
now promises to deliver high volumes of parts
at previously unimaginable speeds. Metal AM’s 194 Advertisers’ index
Vol. 5 No. 3 © 2019 Inovar Communications Ltd Metal Additive Manufacturing | Autumn/Fall 2019 5
engineered
powders
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| contents | news | events | advertisers | website | e-newsletter | Industry News
industry news
Sandvik to begin production of titanium nitrogen levels and will include a high
level of automation, said to ensure
powder at new atomiser plant even better reliability and consistency.
It has a dedicated downstream sizing
Sandvik is adding titanium powder capable of customising materials to and large scale blending and packing
specifically developed for Additive suit customer specifications. facility. The plant will initially produce
Manufacturing to its range of Kristian Egeberg, President of Osprey™ Ti-6Al-4V Grade 5 and
Osprey™ metal powders. A new Sandvik Additive Manufacturing, Osprey™ Ti-6Al-4V Grade 23.
state-of-the-art atomising plant stated, “With 157 years of leading The new titanium powder plant is
for the production of titanium materials expertise and more than located close to Sandvik’s Additive
powders, the result of an investment forty years’ experience in powder Manufacturing Center. With all
amounting to SEK 200 million, will be manufacturing, Sandvik is a true relevant Additive Manufacturing
inaugurated in Sandviken, Sweden, expert when it comes to gas-atomised processes for metals in-house,
on October 22, 2019. AM-powders, as well as in matching Sandvik stated that it can adapt the
With the recent additions of or adapting the materials to the powder to any Additive Manufacturing
titanium and also nickel-based customer’s specific print processes process.
superalloys to its powder offering and applications.” “Besides being a leading supplier
for AM, the company believes that Sandvik’s new state-of-the-art of metal powder for Additive Manu-
it offers one of the widest product titanium powder plant will produce facturing, we have since 2013 made
ranges in the industry. It is also titanium powders with low oxygen and sizeable investments into a wide
range of AM process technologies for
metal components, including Powder
Bed Fusion (Laser and Electron
Beam) and Binder Jetting,” Egeberg
added. “Adding seventy-five years in
post-processing methods like metal
cutting, sintering and heat treatment,
Sandvik has well-established and
leading expertise across the entire
AM value chain.”
In January 2019, Sandvik
merged its Powder and Additive
Manufacturing divisions. As a result,
it now offers services covering the
full metal AM process chain, from
powder production to the supply of
finished AM components. In July 2019,
the company acquired a significant
stake in BeamIT, Italy, an Additive
Manufacturing service provider to the
aerospace, automotive, energy and
The new titanium powder plant is located close to Sandvik’s Additive Manufac- racing industries.
turing Centre (pictured) in Sandviken, Sweden (Courtesy Sandvik) www.additive.sandvik
Carpenter Technology sees GE Additive ships first

strongest quarterly operating Concept Laser M Line
income since 2013 Factory system
Carpenter Technology Corporation, Philadelphia, Penn- GE Additive has shipped its first Concept Laser M Line
sylvania, USA, has announced its financial results for its Factory system from Germany to GE Aviation’s Additive
fiscal fourth quarter and year ended June 30, 2019. For the Technology Center (ATC), Cincinnati, Ohio, USA. The M
quarter, the company reported net income of $48.9 million, Line Factory metal Additive Manufacturing machine has
up from $42.8 million in the same quarter 2018, while net undergone significant changes since the acquisition of
income for the full year 2019 was reported at $167 million, Concept Laser by GE Additive in December 2016, with its
down slightly from $188.5 million in 2018. design architecture, system and software being exten-
Among the fourth quarter’s highlights, it was reported sively reviewed and redesigned in line with established GE
that Specialty Alloys Operations (SAO) had delivered a processes and beta testing.
16.3% operating margin and 20.4% adjusted operating The M Line factory offers a modular machine
margin. Carpenter’s SAO segment manufactures premium architecture in which the units used for part production
alloys and stainless steel, and saw net sales of $532 and for the set-up and dismantling process are physically
million for the quarter (2018: $518.3 million) and $1,967.3 decoupled. This enables these tasks to be carried out
million for the full year 2019 (2018: $1,803.8 million). in parallel and separately from one another, with the
Carpenter’s Performance Engineered Products system’s architecture also said to offer a high degree of
segment, the segment of the company that includes automation of both upstream and downstream stages.
its Dynamet titanium business and Carpenter Powder The modular machine technology is said to be key to
Products (CPP) business, achieved net sales for the fourth Concept Laser’s smart factory concept of a fully expand-
quarter of the fiscal year 2019 of $126.4 million, up from able, automated and centrally controllable production
$116.3 million in the fourth quarter of fiscal year 2018. system, enabling the economical AM series production.
For the full year 2019, the segment reported net sales of www.ge.com/additive
$479.8 million, up from $429.7 million in 2018.
“The fourth quarter marked the end to a successful
year as we generated our strongest quarterly operating
income performance since fiscal year 2013,” stated Tony
Thene, Carpenter Technology’s President and CEO. “Key
highlights of the quarter include SAO delivering 20.4%
adjusted operating margin, positive total company free
cash flow of $115.8 million, and our twelfth consecutive
quarter of year-over-year backlog growth.”
“The fourth quarter’s operating income results were POWDER FLOW CHARACTERIZATION
driven by a continued strong product mix as we generated POWDER SPREADABILITY TEST AND
double digit sequential and year-over-year revenue growth
QUALITY CONTROL
in the aerospace and defence end-use market given our
sub-market diversity and broad platform exposure,” he
continued. “Also, growth in the medical end-use market
remained robust as we continued to benefit from our direct
customer relationships with leading OEMs and increasing
demand for our high-value titanium solutions.”
“This past year we significantly advanced our Additive
Manufacturing platform by adding powder lifecycle
management solutions through the acquisition of LPW
Technology Ltd,” Thene added. “In addition, the expansion
of our soft magnetics capabilities remains on track as we
seek to capitalise on the disruptive impact of electrification
across multiple end-use markets.”
“Looking ahead, we are focused on advancing our
solutions approach, capturing additional productivity and
capacity gains through the Carpenter Operating Model,
and investing in the future of our industry and our end-use www.linkedin.com/company/granutools
markets,” he concluded. WWW.GRANUTOOLS.COM
www.carpentertechnology.com contact@granutools.com | +32 483 19 83 39 | Rue Jean-Lambert Defrêne, 107 - 4340 Awans -
Industry News | contents | news | events | advertisers | website | e-newsletter |
ASL commissions new gas US aerospace company adds

atomiser for AM powders six more MetalFAB1 systems
Atomising Systems Ltd. (ASL), Sheffield, UK, has further Additive Industries North America, Inc., based in Camarillo,
expanded its capacity with the installation of a new 400 kg California, USA, has reported that its largest aerospace
batch gas atomiser aimed specifically at the AM and customer, located in California, has purchased a further six
Metal Injection Moulding (MIM) powder markets. ASL is MetalFAB1 systems from the company, to add to the four it
a specialist in the production of stainless steel powders, has previously installed.
and also produces low-alloy and Ni-based alloys. According to Additive Industries North America, the
The atomiser was designed in-house and is reported prestigious aerospace customer was able to consolidate
to be equipped with ASL’s proprietary anti-satellite and approximately 700 kg of powder in June using the four
hot gas system, resulting in powders that are low in MetalFAB1 systems currently in operation. The company
satellites and high in flowability. The new atomiser can stated that the application represents an inflection point in
produce high yields of MIM and/or AM powders, enabling Laser Powder Bed Fusion (L-PBF) part production, where
ASL to continue to serve its expanding customer base. candidate parts were typically limited to fist-size volumes
“The addition of another atomiser, along with the to meet ROI calculations.
associated sieving and classification equipment, means Using MetalFAB1 systems, this customer is reportedly
that we are able to keep pace with the growth of our able to cost effectively serially produce a part which is 420
existing client base and the requirements of new clients, mm diameter x 400 mm tall and weighs 180 kg. The six new
especially in the AM and MIM sectors,” stated Paul Rose, metal Additive Manufacturing systems are expected to be
Commercial Director. “In these sectors, the benefits of installed at the customer’s facility later this year, bringing
ASL’s anti-satellite technology are clearly recognised its total number of operational MetalFAB1 machines to ten,
through the excellent powder shape and flow properties.” with further installations said to be possible in 2020.
www.atomising.co.uk “This part is likely the largest, most complex L-PBF part
ever produced in series production. We are proud of our
multi-disciplinary team that worked with this customer to
make this production a reality as well as the capabilities
of our MetalFAB1 systems to print for days back to back,”
stated Shane Collins, General Manager for Additive
Industries North America, Inc.
“This order will bring the North America MetalFAB1
installed base to seventeen systems which has been
achieved since the first machine was installed late in
2017. Considering each system has four 500 W lasers, the
powder consolidation capabilities would equal roughly 68
single laser systems.”
Daan Kersten, CEO of Additive Industries, commented,
“The fast growth in North America is partly due to our focus
on the aerospace sector and the aeronautics adoption
curve for production Additive Manufacturing. We expect this
growth to further accelerate when our customers publicly
release their applications and more companies are able
to visualise the large, complex parts that can be manufac-
tured on the MetalFAB1 system in titanium, aluminium,
steel and nickel-based alloys.”
www.additiveindustries.com
Additive Industries’ largest aerospace customer will have

ten MetalFAB1 AM systems (Courtesy Additive Industries)
10 Metal Additive Manufacturing | Autumn/Fall 2019 © 2019 Inovar Communications Ltd Vol. 5 No. 3
Metal Additive Manufacturing
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ExOne reports record second quarter to beta test our new X1 25PRO™,
our larger format, fine powder,
revenues high-resolution production machine
that we displayed at the Rapid + TCT
The ExOne Company, North The company also reported that trade show in Detroit in May. This
Huntington, Pennsylvania, USA, has it had achieved a record-setting new platform is capable of printing
reported record financial results for revenue of $66.7 million in the trailing standard industry powders utilised
its second quarter 2019, as well as twelve months to the end of Q2 2019, in MIM (Metal Injection Moulding)
record-setting trailing twelve month a significant improvement on the and other PM (Powder Metallurgy)
(TTM) revenue. 2017–2018 result of $58.8 million. processes. We secured our first
Consolidated revenue for the Regarding its new X1 25PRO order for a production machine that
second quarter 2019 was reported to metal AM machine, Hartner added, we expect to ship in the second half
be $15.3 million, up 41% compared “As we previously announced, of this year.”
to the same quarter in 2018 and Kennametal and Sandvik have agreed www.exone.com
representing a record level for a
second quarter. The company’s gross
profit for Q2 2019 was reported at
$5.1 million, also said to be a record
result for any second quarter in
ExOne’s history, and representing a
gross margin of 33.7%, compared to
a margin of 14.6% in Q2 2018.
“We are pleased with the
significant progress we are making
– from a technological, commercial
and financial standpoint. We reached
Sintervac® AM debind and sinter
a milestone for ExOne this quarter, vacuum furnaces for Additive
Manufactured parts
reporting record-setting second
quarter revenue and gross profit
levels, in spite of recent unfavourable
macroeconomic factors,” stated John Over 6,500 production and laboratory furnaces manufactured since 1954
Hartner, ExOne’s Chief Executive
Officer. • Metal or graphite hot zones
The second quarter 2019 was • Processes all binders for
said to have benefited from improved metals or ceramics
operating leverage on higher volume, • Sizes from 8-1500 liters
as well as a reduction in fixed costs (0.3–54 cu ft.)
resulting from the 2018 global • Pressures from 10-6 mbar to
cost realignment programme. The Atmosphere
company’s Additive Manufacturing • Precision heat treating post
machines product line achieved the processing available
best results in Q2 2019, reporting • Vacuum, Ar, N2 and H2
$9.3 million revenue, up 187% • Max possible temperature
from $3.2 million in Q2 2018. The 3,500°C (6,332°F)
company’s additively manufactured • Worldwide field service,
products, materials and services rebuilds and parts for all
offering performed slightly less makes
well, reporting Q2 2019 results of
$6 million, down 21% from Q2 2018.
Sintervac® AM
WorkhorseTM AM
Submitting news..
Centorr Vacuum Industries
Submitting news to Metal AM is 55 Northeastern Blvd
free of charge and reaches a global Nashua, NH 03062
USA
audience. For more information Tel: +1 603 595 7233
contact Paul Whittaker:
www.centorr.com/am Fax: +1 603 595 9220
Email: sales@centorr.com
GKN Powder Metallurgy opens new ening collaboration. By discussing

specific business challenges and
customer centre in Bonn evolving industry trends, we can
identify areas of growth potential
GKN Powder Metallurgy has opened company launch customer centres together.”
a new customer centre in Bonn, in Danyang, China, and Auburn Hills, “We have great confidence
Germany, at which customers and Michigan, USA. we’re heading in the right direction
partners can receive support and The Bonn customer centre is because we are working with the
training in all aspects of Powder expected to allow GKN Powder world’s most amazing companies,”
Metallurgy and metal Additive Metallurgy to host tailored visits for added Peter Oberparleiter, CEO at
Manufacturing. The opening is the customers and business partners to GKN Powder Metallurgy. “We’re
third in a year which has seen the meet their specific interests. Visitors developing groundbreaking prod-
to the site can also explore the ucts with our customers, refining
integrated innovation showroom, with 3D printing processes with our
showcases featuring the full range of partners like HP Inc. and EOS, and
GKN Powder Metallurgy’s technology creating our own digital solutions
strategy, and take advantage of its driven by the collective ingenuity of
spacious conference and training our people. GKN Powder Metal-
rooms for hands-on workshops. lurgy’s focus on innovation will
“Today, emerging countries allow us to strengthen our position
can manufacture products of the in the market even more in the
highest quality. This means we have future. “
to further accelerate innovation in GKN Powder Metallurgy employs
Germany,“ stated Guido Degen, more than five-hundred people at
President Additive Manufacturing its IATF 16949-certified production
at GKN Powder Metallurgy. “Our site in Bonn, which was founded in
experience centres are an ideal 1934. The facility currently produces
The new customer centre in Bonn platform for intensifying partnerships over seven million parts per week.
(Courtesy GKN Powder Metallurgy) with our customers and strength- www.gknpm.com
Digital Metal appoints

Christian Lönne as its new CEO
Digital Metal AB, a subsidiary of Sweden’s Höganäs
Group, has appointed Christian Lönne as its new CEO.
Lönne is expected to take up his position on October
8, 2019, with former CEO Ralf Carlström to take a new
managerial position as leader of Höganäs’ investment in
Metal Injection Moulding (MIM).
Lönne most recently worked for the accelerator
Beyond in Lund, Sweden, where he held the position
of head coach for large companies working with lean
start-up methods and open innovation. He is said to offer
many years of international experience from the corpo- Christian Lönne has been appointed CEO of Höganäs
rate world, gained at companies including Sony Ericsson. subsidiary, Digital Metal (Courtesy Höganäs Group)
Lönne has also held leading roles in the growth phase
of companies in both digital technology and consumer
products. Lönne, commented, “I look forward to my assignment
“Digital Metal is ready to take the next step in their at Digital Metal. It is a very exciting company with a high
development,” stated Fredrik Emilson, CEO of Höganäs. level of innovation and cutting-edge technology that has a
“In the future, we will invite other partners to accelerate fantastic potential to change industries. The combination
technological development and increase our global of a dynamic start-up company and a stable owner like
presence. Christian, with his background and experience, Höganäs I see as a success factor.”
is a perfect pilot in developing the business and building a www.digitalmetal.tech
stable commercial platform for Digital Metal.” www.hoganas.com
Industry News
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H.C. Starck Tantalum Sandvik President and CEO to

and Niobium introduces depart company in February
AMtrinsic metal powders Björn Rosengren, President and CEO of Sandvik AB,
H.C. Starck Tantalum and Niobium GmbH, Goslar, Stockholm, Sweden, has informed the Chairman of the
Germany has launched a new range of atomised Sandvik Board that he intends to resign and will leave the
tantalum and niobium powders and their alloys designed company as of February 1, 2020. He will now join ABB, a
specifically for metal Additive Manufacturing processes. multinational automation corporation headquartered in
Under the brand name AMtrinsic®, the new powders are Zurich, Switzerland.
suitable for a wide range of demanding applications. Johan Molin, Chairman of the Board for Sandvik,
Tantalum and niobium, as well as alloys containing stated, “Björn Rosengren has, since he joined Sandvik in
these elements, offer a unique set of properties including November 2015, established a solid decentralised busi-
high melting point, high corrosion resistance, excellent ness model for the company and made the organisation
chemical resistance and high thermal and electrical more flexible and efficient.”
conductivity. This makes them ideal for high-tech applica- “The board is very grateful for his and all the
tions in fields such as chemical processing, superconduc- employees’ work during these years,” he continued. “We
tors, energy and high-temperature environments. will initiate the process to assign a very experienced and
In addition, parts additively manufactured from Ta/ competent industrial leader that can succeed Björn in the
Nb containing alloys may offer an alternative for the role as President and CEO and continue to develop the
optimisation of mechanical and biological performance company even further.”
parameters in medical implants. Multinary alloy composi- “This has not been an easy decision,” commented
tions or high-entropy alloys containing Ta/Nb are said to Rosengren. “Sandvik is a great company with a lot of
be especially of interest for the design of completely new future potential and I will continue to lead the organisa-
intrinsic material properties that can provide superior tion with a strong commitment until the end of January.”
solutions in challenging applications, especially when www.home.sandvik
combined with the freedom of geometric design available
using AM.
“We see the introduction of our new Additive Manu-
facturing brand AMtrinsic as an important milestone in
our new business development activities which should
strengthen our position in the continuously growing AM
Integrated
market,” stated Melanie Stenzel, Head of Marketing and
New Business Development.
www.hcstarck-tantalum-niobium.com InductIon
alloyIng
and atomIzatIon
3D Systems appoints Booth SyStemS
its new Executive VP and CFO
3D Systems, Rock Hill, South Carolina, USA, has
appointed Todd A Booth as its new Executive Vice
President and Chief Financial Officer. Booth will replace
John McMullen, who announced his planned retirement
earlier this year after three years at 3D Systems. Arcast Atomizers are custom built and competitively
Booth has twenty-five years of financial leadership priced to meet the growing demand to produce high
at large and mid-market growth companies as well as quality, low cost, technically advanced metal powders
industry experience in automotive, healthcare, defence, fulfilling the requirements of today’s pioneering
energy, electronics and marine. His most recent role was manufacturing processes.
as CFO for Teledyne Marine where he successfully led a We can supply machines to atomize titanium alloys,
complex, global transformation. super alloys, refractory and reactive metals, and ferrous
“I am excited to have a leader of Todd’s experience join and non-ferrous alloys in high vacuum purged vessels
our team at such an important time for our company,” with inert gas replacement atmospheres.
stated, Vyomesh Joshi (VJ), President & CEO, 3D Systems. We have installed machines all over the world, from
“Todd’s experience leading complex transformations and 1 kg research furnaces to 1000 kg production units.
large-scale efficiency improvements will be invaluable as
we seize the opportunity ahead of us.” www.arcastinc.com
www.3dsystems.com
Enabling you to
print the most
impossible
parts. Heat exchanger printed on VELO 3D’s Sapphire system
that demonstrates ultra-thin features in the core
What if you could design for performance without

consideration of support structures or other constraints
that limit serial additive manufacturing?
Overcome the 45 degree rule-

print low angles down to 10 degrees
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+1(408)610-3915 | info@velo3d.com
Titomic and AP&C Wayland Additive raises

collaborate to develop £3 million in funding round
titanium alloy powders Wayland Additive Limited, Huddersfield, UK, has raised
£3 million in its Series A funding round, led by Longwall
Titomic Limited, a metal Additive Manufacturing
Ventures with the Angel CoFund (ACF), among other
company based in Melbourne, Australia, has announced
investors. The Electron Beam Additive Manufacturing
a supply agreement for Ti6Al4V powders with AP&C, a
company is reportedly developing EB-based systems
GE Additive company, headquartered in Saint-Eustache,
capable of building parts faster and with greater precision
Montreal, Canada. Under the supply agreement, the
than laser-based technologies, and is thought to be
two companies have signed a Memorandum of Under-
targeting end-users in industries such as aerospace and
standing (MoU) which will see them work together to
medical.
develop titanium and titanium alloy powders.
Wayland Additive’s technology is reported to be built on
According to Titomic, the agreement will provide
highly sophisticated developments in scanning electron
a secure global supply of aerospace grade Ti6Al4V
microscopy (SEM) and electron beam lithography, and is
powders for use in its Titomic Kinetic Fusion (TKF) AM
expected to offer very high levels of productivity, material
process. The MoU covers the following cooperation
versatility, process monitoring and control. The company
between the companies:
has acquired IP from Reliance Precision Limited,
• Titomic and AP&C to co-develop industry standards Huddersfield, which has developed AM technologies over
of best practice for the storage and safe handling of the past three years.
titanium and titanium alloy powders The funds raised in this Series A funding round
• Titomic and AP&C to develop custom-made are expected to enable Wayland Additive to develop
homogenisation powder systems for titanium and its advances in metal Additive Manufacturing from an
titanium alloy powders for use in Titomic’s TKF AM advanced prototype to a launch product. The company
systems plans to begin machine shipments in 2021.
• Titomic and AP&C to explore the optimisation of www.waylandadditive.com
coarse (50–150 µm) titanium and titanium alloy
powders for use in TKF AM systems with the aim of
significantly reducing the cost of TKF manufactured
Ry
products.
n a
io
“AP&C, a GE Additive Company, is a global leader
in the production of the aerospace grade titanium and
l u t
o
R ev
titanium alloy powders using its plasma atomisation
manufacturing process, which have the ideal
characteristics for Titomic Kinetic Fusion process,”
stated Jeff Lang, Titomic’s Managing Director. Results demand RevolutionaRy powdeR
“These agreements provide Titomic with not only a
secure metal powders supply from AP&C, a reputable Due to the efficiency of our cutting-
multinational company, but also allows for continuous edge technology we can offer the
improvement under a strong collaboration between the
POWDER lowest priced powder on the market
with no compromise in quality.
parties of their own unique capabilities for future digital
Our powder is:
manufacturing solutions for industries,” he concluded.
• Spherical
Alain Dupont, President & CEO of AP&C, commented, • Free-flowing
“This agreement is a significant milestone in the supply • D50 of 35µm for most materials
of large volumes of titanium and titanium alloy powders, • D50 of 20µm for titanium super alloys
and we’re delighted to be working with a recognised • Has high tap density
leader and manufacturing innovator, Titomic, to We process directly from:
produce best practice standards for the future to lead • Raw elemental material
the development of industry standards for titanium • Pre-alloyed stock
powders.” • Sponge
www.titomic.com • Recycled chip
• Recycled parts
www.advancedpowders.com • Over-sized powder
• We can handle refractory and reactive alloys
www.arcastmaterials.com
ISO 9001:2015 and AS9100D Certified
A division of Arcast Inc.
Renishaw reports mixed 2019 results, AM business reorganisation:

In September, Renishaw reported
considers AM business reorganisation that it was evaluating a potential
reorganisation of its Additive Manu-
Renishaw, Wotton-under-Edge, business had benefited from strong facturing business, with the proposed
Gloucestershire, UK, has reported growth in its Additive Manufacturing co-location of its AM engineering,
challenging economic conditions product line. Renishaw’s Healthcare marketing and commercial opera-
resulted in a drop in fiscal year 2019 business reported a 15% increase in tions at its headquarters in Glouces-
turnover, down 7% to £574 million revenue, reaching £41 million. tershire, UK. The co-location would
(2018: £611.5 million). Adjusted The strongest performing region see the closure of the company’s site
profit before tax amounted to £103.9 for Renishaw in 2019 was still APAC, in Stone, Staffordshire, UK, at the
million, down 28% from £145.1 million achieving full-year revenues of £240.1 end of 2019.
in 2018. million (2018: £289.2 million). EMEA The company explained that, in
The company reported £532.9 followed with revenues of £167.2 the proposed move, its Gloucester-
million revenues from its Metrology million, up slightly from £165.1 million shire headquarters would house an
business, down 7% from 2018 in 2018. In the Americas, the group expanded demonstration facility,
largely as a result of a slowdown in achieved revenues of £132.6 million enabling customers to experience
demand for its encoder and machine (2018: £126.6 million), and in the UK its range of industrial metrology and
tool products in the APAC region. full-year revenues were reported of manufacturing technologies covering
Renishaw added that the Metrology £34.1 million (2018: £30.6 million). process development, Additive
Manufacturing, finish machining and
part verification.
“We have exciting plans for future
systems that will further boost the
adoption of AM for series production,
but in a competitive global business
we need to be agile and efficient in
how we bring these new technologies
to market,” stated William Lee,
Renishaw’s Chief Executive. “Our
current thinking is that the most
effective way to achieve this would be
for our AM technical and commercial
teams to be co-located in our
Renishaw is planning to co-locate its AM technical and commercial teams in its Gloucestershire facilities,”
Gloucestershire facilities (Courtesy Renishaw) www.renishaw.com
Markforged files legal complaint against as we know it, and Markforged

is leading the charge. We believe
Desktop Metal healthy competition is good for the
industry, innovation, and – most
Markforged, Inc.,has filed a complaint found in favour of Markforged, and importantly – customers. Unfortu-
in the U.S. District Court for the the companies were reported to have nately, as alleged in our complaint,
District of Massachusetts against reached an amicable resolution in Desktop Metal has chosen to
Desktop Metal, reports Boston October 2018. compete by spreading false informa-
Business Journal. The company is At the time of the agreement, a tion. Markforged is taking this
said to have requested a trial by jury mutual non-disparagement clause necessary step to ensure customers
to address its claims that Desktop was agreed, prohibiting Desktop are making their buying decisions on
Metal has spread “falsehoods” about Metal from “misrepresenting the facts, not lies.”
Markforged’s products. functionality of Markforged’s prod- A spokesman for Desktop Metal
This latest legal complaint follows ucts.” The companies were in October commented, “We are aware of the
an earlier patent infringement lawsuit reported to have agreed that $100,000 filing by Markforged and believe the
filed by Desktop Metal in March in liquidated damages would be paid claims are without merit. We will
2018, in which the company alleged for each violation of these terms. be addressing the allegations in the
that Markforged’s Metal X Additive When contacted for comment, appropriate forum.”
Manufacturing system violated two Markforged stated, “Metal 3D printing www.markforged.com
of its patents. In this lawsuit, the jury is on pace to change manufacturing www.desktopmetal.com
Hirtenberger. Ingenuity. Engineered
HIRTISATION®
FULLY AUTOMATED POST-PROCESSING
OF 3D-PRINTED METAL PARTS
No mechanical processing steps involved Removal of powder cake

Reaching deeply into cavities and geometric undercuts Removal of support structures
Combination of electrochemical pulse methods, hydro- Levelling of surface roughness while retaining
dynamic flow and particle assisted chemical removal edge sharpness
Hirtenberger Engineered
Surfaces GmbH
Leobersdorfer Strasse 31-33
2552 Hirtenberg/Austria
Phone: +43 2256 811 84-835
MEET US @ FORMNEXT 2019
E-Mail: hes@hirtenberger.com BOOTH 11.0 - E11
Stratasys reports strong Digital Metal launches two

performance in Americas superalloy grades
Stratasys Ltd., based in Minneapolis, USA, and Rehovot, Digital Metal AB has launched two superalloy grades for
Israel, has announced financial results for the second metal Additive Manufacturing, said to be suitable for use
quarter 2019, reporting a slight fall in revenue to $163.2 in extreme environments. The materials are DM 247, a
million, compared to $170.2 million in Q2 2018. Gross nickel-based superalloy, and DM 625, a nickel-chromium
profit was $81.2 million, compared to $83.6 million in the superalloy.
same period in 2018. However, with operating expenses The company states that, although the strength and
of $80.4 million in Q2 2019, the company posted a corrosion resistance of superalloys makes them suitable
$805,000 operating profit for the period, compared with a for use in challenging applications such as aerospace,
$1.9 million loss in Q2 2018. automotive and chemical, it has been difficult to use non-
“Our second quarter results reflect continued strong weldable materials such as MAR M247 in AM, where high
performance in the Americas, where we saw revenue solidification rates and thermal gradients are inherent.
growth across systems, consumables and services, According to Digital Metal, its unique Binder Jetting
which was offset mainly by significant economic weak- technology helps to avoid most of these problems by
ness in Europe that we believe is impacting capital additively manufacturing in an ambient temperature
investments and general spending in the automotive and without applying any heat, followed by a separate sintering
industrial machinery markets in that region, as well as by step. Sintering densification takes place without melting
the adverse impact of foreign exchange rates in Europe and with minimal thermal gradients occuring during
and Asia-Pacific,” stated Elchanan Jaglom, Interim CEO cooling from the sintering temperature.
of Stratasys. “We believe that we are well-positioned The DM 247 grade is based on the non-weldable MAR
to return to growth in Europe when macro conditions M247, which is widely used as material for turbine blades
improve, and our new products and platforms are and in other applications with elevated temperatures. DM
launched and adopted in the market.” 625 is an Inconel 625-grade material and its application
www.stratasys.com areas range from chemical processing equipment to
applications in the nuclear industry and aerospace sector.
“We have been receiving qualified requests for these
materials from various large companies,” stated Ralf Carl-
ström, General Manager, Digital Metal. “Many producers
COMPLEX within the aerospace and automotive business have

long been anticipating high-quality superalloys that are
PART WANTED suitable for 3D printing. Now we can offer them the perfect
combination – our unique Binder Jetting technology and
Complete solution found superalloys that are specially developed for our printers.”
www.digitalmetal.tech
NSERC’s HI-AM network

expands collaborations
3D METAL PRINTING AT TOOLCRAFT –
EVERYTHING FROM A SINGLE SOURCE The Natural Sciences and Engineering Research Council
of Canada (NSERC)’s network for Holistic Innovation in
++ Most complex components made of high perfor-
Additive Manufacturing (HI-AM) has announced a number
mance alloys ++ Increase in economic efficiency
of international collaborators to enhance its AM research
due to significant reduction in resources and weight
and create training opportunities for its students.
++ Topology optimisation and FEM calculations ++
The HI-AM network brings together seven Canadian
Latest machinery, state-of-the-art analysis technology
universities to investigate the fundamental scientific
and vacuum heat treatment
issues associated with pre-fabrication, fabrication and
post-fabrication of components by a range of AM tech-
nologies, with a primary focus on structural metals.
Joining the network as international collaborators
were Fraunhofer Institute for Manufacturing Technology
and Advanced Materials (IFAM), Fraunhofer Institute for
More details: Material and Beam Technology (IWS), University of Twente
www.toolcraft.de/en/metal-laser-melting and RMIT University.
www.nserc-hi-am.ca
ADDITIVE BY SANDVIK
LET’S ADD THE MATERIAL DIFFERENCE
Metallurgists, world leading powder producers, post processing and metal cutting experts.
With 157 years in the metal industry, few understand the secrets of additive manufacturing
like Sandvik. With leading expertise across the additive value chain, we take you all the way
from concept to serial production. With our in-house powder manufacturing capabilities and
leading Osprey™ metal powders, we also offer the widest range of AM-alloys around – now
also including vacuum melted nickel-based superalloys and titanium. Our facilities fit all
relevant additive manufacturing processes for metals under one roof – meaning we can
tailor our powders to any printing process.
MEET OUR ADDITIVE MANUFACTURING AND POWDER EXPERTS AT:

TCT Korea - Stand F28 Materials Pavilion | October 16-18 | Changwon, South Korea.
Formnext - Hall 11.0 Stand B19 | November 19-22 | Frankfurt, Germany.
TCT Japan - Stand 4S-A04 | January 29-31 | Tokyo, Japan.
additive.sandvik
MUT Advanced Heating celebrates its MUT has customers in the glass
and ceramic, metalworking, Powder
25th anniversary Metallurgy, carbon and chemical
industries. The company designs
MUT Advanced Heating GmbH, complex manufacturing processes, systems for modern processes
headquartered in Jena, Germany, the company states. Developments in in sintering, debinding, joining
is celebrating its 25th anniversary. materials science have fundamentally techniques, heat treatment of
Founded by Heinz-Jürgen Blüm changed the required thermal aggressive substances as well as in
in September 1994, the company processes. To meet these needs, MUT the areas of high pressure and hot
originally focused on environmental builds customised systems offering gas. A joint venture with Element
technology before moving into higher efficiency, as well as the 22 GmbH in 2006, creating TiGen
thermal processing. It was then associated degree of automation now (Titanium Generation GmbH), also
rebranded as MUT Advanced Heating required in many thermal installations. provides solutions for the titanium
GmbH in 2003, and has since The company’s certifications for sector that include heat treatment
concentrated on the engineering manufacturing pressure vessels (HPO and sintering plant for titanium
and production of high-temperature authorisation and welding fabricator and other reactive metals that have
furnace technology, both with defined certification) also enable it to define been produced by MIM, AM or other
atmospheres and under vacuum. the optimal plant selection with its forming processes.
Increasing demands on the customers, and guarantee performance A new range of heat treatment
materials sector lead to increasingly on the basis of certified processes. products, specifically developed
to meet the demands of Additive
Manufacturing processes, have also
been introduced. These include
suitable furnace technology for
powder processing, debinding
and sintering as well as for heat
treatment. “Even after 25 years, we
are still taking on new challenges
that accompany advancing develop-
ments in the fields of materials,
energy engineering, and production
and process technology,” the
company stated.
“We would like to give a hearty
thank you to all our customers,
partners, suppliers and employees
for the trust and loyalty they have
MUT founder, Heinz-Jürgen Blüm, with one of the company’s debind and sinter shown to us over past years.”
furnaces (Courtesy MUT Advanced Heating GmbH) www.mut-jena.de
Markforged unveils new ‘Print Farms’ Sinter-2 is the optimum package to

maximise output. A properly balanced
for metal and carbon fibre AM print farm helps companies accelerate
their transition to digital manufac-
Markforged, Watertown, Massa- Markforged Print Farms are turing.”
chusetts, USA, has unveiled its new managed from a centralised, cloud- Markforged’s metal AM systems
‘Print Farms’ – described as an based software program, and are said can produce parts in 17-4PH Stainless
economic way for customers to build to enable access to a full range of Steel, H13 Tool Steel, and A2 Tool Steel.
their metal and carbon fibre Additive industrial materials on one platform This month, Markforged is expected
Manufacturing capacity with Mark- and the opportunity to additively to add D2 Tool Steel, a high-carbon,
forged. The new Print Farm packages manufacture multiple materials in high-chromium tool steel that can be
allow customers to purchase Metal X parallel. Jon Reilly, VP of Product heat treated to a very high hardness.
systems and carbon fibre X7 printers, at Markforged, commented, “We This material offers high wear resist-
priced together, to rapidly additively are introducing Print Farms to help ance and is widely used in cold work
manufacture metal, composite, customers maximise the efficiency applications that require high compres-
and hybrid parts that leverage both of our Metal X systems. Three-to-five sion strength and abrasion resistance.
materials for high-throughput AM. Metal X printers, one Wash and a www.markforged.com
GF Machining Solutions
DMP series
Production-oriented
metal 3D printers
Based on 3D Systems’ proven precision metal 3D printing
technology and GF Machining Solutions’ technical and
industrial knowledge, the DMP series is engineered for
repeatable part quality and high productivity with a low
total cost of ownership and smooth integration into
traditional metal manufacturing processes.
Unique vacuum chamber concept
High repeatability for

high-quality parts
Unique modular concept
Optimized productivity
and powder recyclability
3DXpert™ all-in-one software
Simplified metal AM
process workflow
www.gfms.com
Visit us at
Formnext
Hall 12.1
Booth D19
DMP Flex 350 DMP Factory 500

Melrose announces 2019 half

year results, GKN on track to
achieve targets
Melrose Industries PLC has announced its interim
financial results for the six months ended June 30, 2019.
The company reported half year revenues of approx £6
billion, a significant rise from £2.97 billion in the first
six months 2018. Operating profit was reported at £539
million, up from £284 million in the first six months 2018.
Melrose acquired GKN plc, including GKN Powder
Metallurgy, the world’s largest producer of Powder
Metallurgy components, for £8.1 billion in April 2018.
In its 2019 half year results, the company stated that
the three main divisions of GKN are on track to achieve
previously announced targets.
Of particular note was that Automotive and Powder
Metallurgy divisions were maintaining profit well in
an automotive industry downturn, due it was said to
Melrose’s decisive cost reductions. It was also stated that
many operational improvement programmes and capital
investment projects were underway to help improve
performance further, while good progress is being made
on resolving the GKN loss-making contracts.
Further, a new target to improve GKN’s working capital
efficiency is expected to release additional future free
cash of £400 million within Melrose’s ownership period.
The company added that it has made record investments
in aerospace technology so far in 2019, and announced
plans to create the ‘One GKN Aerospace’ organisation
with the aim of further improving performance in this
sector.
Justin Dowley, Melrose Chairman, commented on
the results, “These results show the initial fruits of the
‘improve’ stage of Melrose’s ownership of GKN and, with
the overall GKN margin increasing positively, we are
excited about what is possible. The performance is in line
with expectations and leverage is better than expected.”
“At the same time, this has been a year of record
investment in aerospace technology and substantial
eDrive development,” he continued. “The Melrose Board
is confident that our businesses will deliver significant
upside for shareholders.”
www.melroseplc.net
www.gkn.com
Submitting news..
Submitting news to Metal AM is free of charge and
reaches a global audience. For more information
GF Machining Solutions
CUT AM 500
Unique EDM separation
of AM parts
Live at
Formnext
Hall 12.1
Booth D19
Horizontal cutting process
Easy setup, no part damage

Fast and robust separation process
High cutting speed, avoids wire breakage

Collection basket
Protects part integrity, improves traceability

Innovative wire-cutting EDM solution
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www.gfms.com
Industry News
IT IS our
ImagInaTIon
that inspires us to turn the
seemingly impossible into reality.
To make dreams come true, we trust in our imagination and creativity, which inspire us
to seek new solutions and processes. In this way, by committing today to such innovative
technologies as additive manufacturing – 3D printing with metals – we are paving the
way to the future. Turning passion into technology.
voestalpine High Performance Metals GmbH

www.voestalpine.com/additive
GE’s Arcam EBM and Concept Steady revenues at Sandvik

Laser open new facilities despite drop in Q2 orders
GE Additive has reported the opening of its Arcam EBM Sandvik AB, headquartered in Stockholm, Sweden, has
Center of Excellence in Gothenburg, Sweden, along reported revenues for the group remained steady in the
with the inauguration of its Concept Laser campus in second quarter 2019 at SEK 26,467 million (apx $2,673
Lichtenfels, Germany. million), with adjusted operating profit for the period down
Arcam EBM’s new 15,000 m2 facility is reported to 2% at SEK 4,968 million (apx $502 million). Order intake
have capacity for up to 500 employees, tripling the floor was reported to have declined by 5% and the adjusted
space of the company’s Mölndal site. According to GE operating margin declined to 18.8%.
Additive, having production, R&D, training facilities and Sandvik Materials Technology, which includes the
support functions housed under one roof allows it to groups metal powder division, saw a decline in organic
put lean manufacturing at the heart of its operations to orders of 20% year-on-year. Adjusted operating profit
increase production capacity. As more industrial additive however (excluding the effects of metal prices) was up
users begin to make the shift to serial production, the 9% at SEK 585 million ($59 million) and the adjusted
company stated that demand for its Arcam EBM systems operating margin improved to 14.6%. It was stated that
is continuing to grow. the internal separation of Sandvik Materials Technology,
“The Arcam EBM team in Gothenburg is energised to announced in May, has now been initiated with the Board
be in its new home – a dynamic, sustainable workplace of Directors also exploring the possibility of a separate
– in a great location. We will harness that energy and listing on the Nasdaq Stockholm Exchange.
continue to research, innovate and drive EBM technology “During the quarter, we announced new ﬁnancial and
further,” stated Karl Lindblom, General Manager GE sustainability targets. I am conﬁdent that Sandvik will
Additive Arcam EBM. deliver improved performance throughout the economic
During a ceremony in Lichtenfels, Germany, GE cycle,” stated Björn Rosengren, President and CEO.
Additive officially opened its new 40,000 m2 campus. www.home.sandvik/en/
Known as GE Additive Lichtenfels, the site will become
the new home for GE Additive Concept Laser. The campus
has capacity for up to 700 employees, and the transition
of production from the current Concept Laser site to the
new facility will continue throughout 2019. A planned
office block is also currently under construction, and is
scheduled for completion in 2020.
Jason Oliver, GE Additive’s President & CEO,
commented, “Today is a great milestone for GE Additive,
for Frank and Kerstin Herzog and the entire Concept
Laser family. There has been a lot of interest in the
building over the past three years, both locally and from
our customers. We want this modern, Lean manufac-
turing production facility, here in Bavaria, to become a
Rapidox 2100-OEM-RSB
global focal point for the additive industry.”
www.ge.com/additive
Small but mighty.

The compact design (4.5” x 3.0”) allows
integration into the tightest of spaces yet comes with
the same performance specifications and features of our
exisiting OEM analysers. The board is fitted with a
robust cabled zirconia sensor, which is ideal for
providing fast and accurate remote in-situ gas
analysis over the the full oxygen range 10-20ppm to 30% O2.
Contact us today:
www.cambridge-sensotec.co.uk
sales@cambridge-sensotec.co.uk
+ 44 (0)1480 462142
GE Additive opens its Arcam EBM Center of Excellence in
Sweden (Courtesy GE Additive)
PIM showcase to promote

MIM and CIM technology at
Formnext 2019
Virtual A major showcase of more than a hundred components
manufactured by Metal Injection Moulding (MIM) and
Additive Manufacturing Ceramic Injection Moulding (CIM) will be held at Formnext
2019, taking place in Frankfurt, Germany, November
19-22. These processes, which come under the umbrella of
Powder Injection Moulding (PIM), enable the high-volume
production of net-shape, high-precision components from
a diverse range of materials, including stainless steels,
superalloys and titanium alloys.
Organised by PIM International in partnership with
Mesago Messe Frankfurt GmbH, the showcase is designed
to highlight the capabilities of PIM technology and its broad
range of application areas. These include the automotive,
aerospace, consumer electronics, medical and general
engineering sectors.
Sascha F Wenzler, Vice President of Formnext at
Mesago Messe Frankfurt, stated, “As the leading global
exhibition and conference on Additive Manufacturing and
the next generation of intelligent industrial production,
Powder Injection Moulding fits perfectly into the scope of
Formnext. We are delighted to be able to showcase the
capabilities of MIM and CIM to our international visitors.”
“Since its launch, Formnext has seen visitor numbers
Predictive Simulation for: increase dramatically, from 9,000 visitors in 2015 to nearly
Metal | Polymer |Ceramic 27,000 in 2018. Made up of product designers, manage-
ment, engineers, technicians and entrepreneurs from an
impressive range of end-user industries, this is an ideal
audience to present with this group of dynamic technolo-
✓Reduce: gies, to the benefit of both our visitors and the industries
o Trial & Error, Material Waste, Engineering Time we represent,” added Wenzler.
Nick Williams, Managing Director of Inovar Commu-
✓Predict: nications Ltd, stated, “The success of the metal Additive
Manufacturing industry since the inaugural Formnext
o Voids, Residual Stress, Surface Roughness,
exhibition in 2015 reflects a growing acceptance of the use
Crack Growth of metal powders for the production of high-performance
end-use components for both general engineering and
✓Assess: critical applications.”
o Material & Process Parameter Sensitivities “As technologies that have much in common with
metal AM, both in terms of the starting powders and also,
in the case of metal Binder Jetting and Fused Filament
✓Perform: Fabrication, the binders and the sintering equipment used,
o In-Service Qualification of Printed Part MIM and CIM are a natural fit. Through our publication
PIM International, we are excited to be able to cooperate
with the Formnext team to promote the technology on such
an important stage.”
The showcase, located in Hall 11.0, Stand A51, will
feature parts from Europe, North America and Asia and
includes award-winning parts from the European Powder
Metallurgy Association and Metal Powder Industries
Federation‘s Metal Injection Molding Association along
with numerous application examples from Germany’s MIM
Expert Group and CIM Expert Group.
www.alphastarcorp.com www.formnext.com
Cytosurge announces spin-off of its

micro-scale metal AM business unit
Cytosurge AG, Glattbrugg, academic research in the field of
Switzerland, has announced a spin-off cell- and bioscience.
of its Additive Manufacturing business Dr Pascal Behr, CEO of Cytosurge,
unit, stating that the new company stated, “Given the unique nature
will focus on providing solutions for of the Additive Manufacturing
processes and instruments in the business and specific requirements
field of microscopically small metal of our key target markets such as
components. The new independent the semiconductor industry, we
entity will operate under the name are convinced that an independent
Exaddon AG, and will be led by Edgar company can realise the high growth Copper microneedles can be custom-
Hepp, who takes the role of CEO. opportunities in this emerging market ised to suite individual applications
According to Cytosurge, the much better if it can focus entirely (Courtesy Exaddon)
establishment of the spin-off on this key goal. We are very proud to
company was initiated by exploring announce today the establishment of
the applicability of its proprietary Exaddon AG for this purpose and I am products at an unprecedented level,”
FluidFM® technology to the field convinced that Edgar and his team commented Hepp. “Exaddon AG is
of additive micro-manufacturing. will thrive.” now responsible for all Cytosurge
Originally developed at ETH Zurich “We have developed a ground- AG projects related to Additive
a decade ago, FluidFM has already breaking manufacturing technology Manufacturing and will continue to
resulted in several highly innovative and have brought it to market manage and develop them.”
solutions for customers in the maturity. It enables our clients to www.cytosurge.com
pharmaceutical industry, as well as additively manufacture high-end www.exaddon.com
25 YEARS INDIVIDUAL HEAT TREATMENT

innovative furnace systems
made in germany Hall 11.1 Booth E79
mut-jena.de
ISO
Integrated Sintering and
Debinding Oven
Sintering and
YOUR
thermal debinding
in one process
OUR
EXPERIENCE SUCCESS
MUT ADVANCED HEATING

Automated
powder removal
- Reproducible cleaning results

- Examined protection against hazardous
& explosive metal dust
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- Built to last with low maintenance costs
- Time saving up to 90%
Hall 12, C119
engineered
and made
solukon.de in Germany
Equispheres’ success in sintering of

aluminium alloys for binder jet AM
Equispheres, a materials science Equispheres is reportedly
company based in Ottawa, Canada, in working with McGill University, as
collaboration with McGill University, well as other key partners, on the
Equispheres’ aluminium alloy
Montreal, Canada, has confirmed that development of specialised binder
powders (Courtesy Equispheres)
after extensive testing, Equispheres’ agents for aluminium and specific
aluminium alloy powders are suitable automotive applications. The company
for sintering following binder jet is optimistic that the process and nents and the fundamental relations
Additive Manufacturing. powder will offer a new high standard with new specialised binder agents.”
According to the company, until now for many critical parts as the process Kevin Nicholds, Equispheres’
binder jet AM technology was unable is refined and testing continues. CEO, commented, “We are excited
to produce sinterable aluminium alloy “The unique and tailored attributes about the industry response to our
parts, largely due to aluminium’s of Equispheres’ powder have proven unique aluminium sintering results.
oxide layer. Equispheres states that exceptional in compaction free Although binder jet printer technology
the powder it has developed will make sintering,” stated Dr Mathieu Brochu, offers the speed and cost reductions
sintering of aluminium alloy parts Associate Professor at McGill and necessary to enable Additive Manu-
viable due to its thinner oxide layer and Canada Research Chair in Pulse facturing to meet the requirements
smoother surface. The specific findings Processing of Nanostructured of automotive mass production, the
of its testing include: compaction-free, Materials. “We are excited to begin inability to print with aluminium alloys
sub-solidus sintering of the company’s work with Equispheres’ Binder Jet has been a major limitation to the
standard AlSi10Mg aluminium alloy printing partners in the next phase to technology – until now.”
powder, good densification (> 95%) and fully understand all aspects related to www.equispheres.com
excellent microstructure. sintering of complex shape compo- www.mcgill.ca
It’s a matter
of choice
CM has been involved in the
additive market since its inception.
We offer both tube and box
furnaces in a variety of sizes.
Both have multiple atmosphere
capabilities.
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info@cmfurnaces.com
103 Dewey Street Bloomfield, NJ 07003-4237 | Tel: 973-338-6500 | Fax: 973-338-1625
Xerion launches ultra-compact Fusion

Factory debinding and sintering system
Xerion Berlin Laboratories GmbH, and more. However, one factor that
Berlin, Germany, has launched a has held back the industrial use of
new ultra-compact Fusion Factory the process is that individual pieces
debinding and sintering unit with of equipment for debinding and
external dimensions of 1,200 x sintering had to be purchased from
1,000 x 2,000 mm. different manufacturers.
In contrast to its first Fusion With Xerion’s ultra-compact
Factory system, released 2018, Fusion Factory debinding unit and
which combines a Fused Filament the sintering furnace, both systems
Fabrication (FFF) system for metal are available from the same
and ceramic parts with a debinding manufacturer and take up limited
and sintering system in one space in the production environ- Xerion’s ultra-compact Fusion Factory
modular unit, this compact system ment. In accordance with the BASF debinding and sintering unit (Courtesy
does not include the FFF system, CATAMOLD® principle, debinding is Xerion Berlin Laboratories GmbH)
but enables the post-processing of carried out by catalytic means, while
FFF parts within twenty-four hours. the sintering furnace can reach
The main advantages of the temperatures of up to 1,450°C under Factory to develop their own
FFF process include freedom from protective gas conditions. Sintering filaments and sintering strategies
the tooling costs associated with under a 100% hydrogen atmosphere for FFF. To enable this research,
MIM and CIM, cost-effectiveness is also possible. the system supports an open
when compared to other metal AM A number of research institutes architecture.
processes, short production times are now said to be using the Fusion www.xerion.de
OUTPERFORM
Dies for: Compression • Stamping • Forging • Extrusion • Die Casting
Hot/Cold Working • Faster Die Delivery

• Lower Life Cycle Cost
Tool Steel Material for • Longer Die Life
Powder Bed Fusion
LEARN MORE:
FORMETRIXMETALS.COM
INFO@FORMETRIXMETALS.COM
Formerly NanoSteel Additive Manufacturing
Rapidia ships its first water-based debinding step and is said to result
in a fast, simple to use system that is
bound metal paste AM system environmentally friendly.
Complex internal structures are
Rapidia Inc, Vancouver, British Rapidia system will reportedly serve made possible using proprietary
Columbia, Canada, has begun several start-ups located at the evaporative polymer supports. These
commercial shipments of its facility. supports are said to be unique to
solvent-free water-based metal The Rapidia system builds parts Rapidia, and are made possible by the
Additive Manufacturing system. The using a novel water-based bound water-based metal paste. By elimi-
first machine has been installed at metal paste AM process, followed nating the debinding stage, polymer
the Hatch Accelerator, a start-up by a final sintering stage. The use supports can be retained until the
incubator based at the University of water, instead of a typical binding sintering stage, by which point the
of British Columbia, where the new element, eliminates a solvent-based part is strong enough to support itself.
These evaporative supports are used
for almost all supports, substantially
reducing post-processing time and
cutting the amount of metal wasted
on supports by up to 90%.
Currently, both 17-4PH stainless
steel and Inconel 625 alloys are avail-
able for use in the Rapidia system.
Under development are copper, 316L
stainless steel, tungsten carbide, H13,
titanium and alumina.
The system can build components
from CAD file to finished metal part,
including sintering, in around twenty-
four hours. A number of further
installations are said to be planned
Rapidia uses water-based metal paste supplied in ready to use cartridges over the coming months.
system (Courtesy Rapidia) www.rapidia.com
MSC Software and MIG partner on teaching initiatives, I believe we will

provide the opportunity to introduce
microstructure simulation for AM new material, design and product
innovations in healthcare, defence and
MSC Software, Newport Beach, products in conjunction with educa- transportation.”
California, USA, and the Materials tion in the techno-economic aspects The MIG is currently collaborating
Innovation Guild (MIG) at the Univer- of AM to enhance its competitiveness with NASA on a new metal Fused
sity of Louisville, Kentucky, USA, have in product and manufacturing design. Filament Fabrication process which
launched a new research collabora- The consistency of material it calls MF3. MF3 will be simulated in
tion focused on advancing Additive properties in new designs remains the Digimat-AM product as part of the
Manufacturing technologies through a barrier to the adoption of AM in collaboration. Dr Kunal Kate, Assis-
microstructure simulation. Through high-performance and high-reliability tant Professor at the University of
the MIG, the University of Louisville applications. MIG research will use Louisville, explained, “MF3 or similar
assists organisations such as NASA MSC Software’s Simufact and Digimat powder-binder based 3D printing
and Boeing in the development of modelling and simulation platforms processes require post-processing
Additive Manufacturing programmes, to understand the fundamental steps of debinding and sintering, that
as well as training future engineers materials properties and microstruc- are currently subject to trial-and-error
in new design and production ture in metal powders, polymers and experiments. Combining experimental
techniques. composites, and how to exploit the research with the capabilities of
Under the partnership, MSC relationship between materials and MSC Software can develop new tools
Software will support the university’s design in AM. that predict 3D printed part material
on-site and distance learning by Dr Sundar Atre, Endowed Chair properties and effectively capture post
supplying software and training. of Manufacturing and Materials at debinding and sintering effects for
Start-ups in the university’s 3D the MIG commented, “By integrating powder-polymer based 3D printing,”
Printing Business Incubator will MSC’s Simufact and Digimat http://scipivision.scipitutors.com/
also have access to MSC Software platforms into MIG’s research and www.simufact.com
High Pressure Heat Treatment.
At the Heart of Lean Additive
Manufacturing
Photo courtesy of Sintavia, LLC.
The global leader in high pressure technology

Quintus Technologies specializes in the design, manufacture,
installation, and support of high pressure systems for sheet
Visit us in booth
metal forming and densification of advanced materials and
11.0 – D03 at Formnext
critical industrial components. November 19-22, 2019.
Messe Frankfurt, Frankfurt,
Headquartered in Västerås, Sweden, and represented in
45 countries worldwide, the company is the world leader in
high pressure technology and has delivered more than 1,900
systems to customers across the globe within industries such
as aerospace, automotive, energy, and medical implants.
Do you want to know how HIP and heat treatment can help
you become more competitive by increasing your productivity
and reducing your post processing costs?
Visit www.quintustechnologies.com for more information!
www.quintustechnologies.com
AddSteel project complex parts in small series. L-PBF

is already being used by companies
of new components and spare parts
that will be used to test and validate
looks to develop in the aerospace, turbomachinery, the materials’ performance and
new steels for AM medical device and other industries
to produce complex functional
cost-efficiency.
A plant has already been built at
components. SMS group that can atomise suit-
The federal state government of The AddSteel project partners able metal powders and Deutsche
North Rhine-Westphalia, Germany, have reportedly chosen to develop Edelstahlwerke Specialty Steel is now
has launched the NRW Leitmarkt alloys in an iterative process, supplying the alloys that Fraunhofer
project AddSteel, aimed at digitalising combined with systematic adjust- ILT will soon be testing on its L-PBF
the steel industry. Coordinated by ments to the L-PBF process and system, after the alloys have been
SMS group GmbH, the three-year equipment. This will be followed converted into powder form.
project aims to develop new function- by the construction of technology www.sms-group.com
adapted steel materials for Additive demonstrators for the fabrication www.ilt.fraunhofer.de
Manufacturing. In addition to SMS
Group, the project’s four participants
include Fraunhofer ILT, Deutsche
Edelstahlwerke Specialty Steel GmbH
& Co. KG and Aconity GmbH.
One of the project’s key areas of
Optimise Your
focus is the qualification of newly
developed materials for Laser Powder
Bed Fusion (L-PBF) at the Fraunhofer
Institute for Laser Technology (ILT)
in Aachen, Germany. One of the AM Build Process
AddSteel project team’s first reported
successes was the development of (and beyond …)
case-hardening and heat-treatable
steel powders designed specifically
for L-PBF applications.
According to Fraunhofer ILT,
steelmakers in Germany are facing a
continuing decline in sales. Previ-
ously, efficiency was increased by
modifying manufacturing processes
and equipment. Now, however,
rative Design
Also available: Gene
developers and users are increasingly
turning their focus to the alloys to be
processed. Innovative materials are
expected to offer new potential for
competitive advantages.
The steel industry requires new
materials to meet its customers’
increasingly complex demands for Higher efficiency by automation and assistant functionality
products they can use, for instance, Optimise your 3D printing by Generative Design and
to manufacture lightweight and Process Simulation
crash-resistant components for the Identify the best build orientation
automotive sector. AM processes such Determine and compensate final part distortion automatically
as L-PBF are extremely useful for Generate and optimize support structures automatically
Meet the Experts for the Simulation
lightweighting and part optimisation, of Generative Design and Metal Use Materialise support generation functionality
and give users the opportunity Additive Manufacturing at the Identify manufacturing issues, such as cracks,
to sustainably optimise the steel formnext show in Frankfurt in hall shrinklines, recoater contact
industry’s value chain. 12 at the Hexagon booth B 79.
In recent years, scientists at
Fraunhofer ILT have been working on
developing L-PBF technology from a Nov. 19-22
prototyping method to an industrial- Frankfurt /Main
scale method for the production of
DNV GL awards thyssenkrupp

Additive Manufacturing
Approval of Manufacturer
certificate
DNV GL, a classification society headquartered in Oslo,
Norway, has awarded thyssenkrupp AG, Essen, Germany,
the first Additive Manufacturing Approval of Manufac-
turer certificate.
The society states that the certificate makes
thyssenkrupp the world’s first producer of additively
manufactured parts for maritime applications to obtain An additively manufactured probehead produced by thys-
manufacturer approval from DNV GL. Certification was senkrupp from austenitic heat resistant steel (Courtesy
important for thyssenkrupp Marine Systems, as the DNV GL/thyssenkrupp)
company reports that it is working with international
customers on the integration of AM parts on ships and
submarines. “Additive Manufacturing will have a significant impact
According to DNV GL, the approval covers the Additive on the future maritime value chain,” stated Geir Dugstad,
Manufacturing and processing of austenitic stainless Director of Ship Classification & Technical Director of
steel parts. Certification was also awarded for the DNV GL – Maritime. “Producing components that have
acceptance process in accordance with EN 10204 and the the same level of quality as conventionally manufactured
associated product information, particularly the chemical parts and fulfil class requirements is key.”
and physical material characteristics. Dugstad added, “At DNV GL, we are very pleased
to certify that the thyssenkrupp TechCenter Additive
Quarter Page draft 3.pdf 1 26/09/2019 16:17:09 Manufacturing has demonstrated its ability to reliably
produce metallic materials using Additive Manufacturing.
This is the first time DNV GL has awarded its Approval of
SIL Rated Technology Manufacturer certificate, and I would like to congratulate
thyssenkrupp on this achievement.”
Dr Luis Alejandro Orellano, Chief Operating Officer,
thyssenkrupp Marine Systems, commented, “We are
delighted that with thyssenkrupp TechCenter Additive
Manufacturing we now have a certified partner who can
supply thyssenkrupp Marine Systems with additively
manufactured parts that meet both our own and our
customers’ high expectations. Together we are putting
innovative solutions into our submarines and ships,
C
setting new standards for the navy of the future.”
M
“A team effort was particularly important here, as the
Y certification required us to rethink traditional methods
CM
for quality evaluation and certification,” explained Eva
Introducing the latest SIL Rated Microx Junghans, Senior Principal Engineer, Materials & Welding
MY
Oxygen Analyser from Ntron at DNV GL – Maritime. “I would like to thank everybody
CY
Designed for OEMs to address the involved for their support and collaboration.”
need for a compact and reliable
CMY www.dnvgl.com
oxygen analyser within their
K safety critical process. www.thyssenkrupp.com
With an oxygen measurement
range from 1 PPM to 25% oxygen
and the choice of single or dual
sensors (SIL1 / SIL2), the Microx
is the perfect addition to your
additive manufacturing process. Submitting news..
Submitting news to Metal AM is free of charge and
reaches a global audience. For more information
www.ntron.com
US Department of Defense awards demonstration of closed loop control.

Flyware states that this essentially
contract to extend Flightware’s in-situ eliminated the initial flaw porosity
inspection method (up to 14%) and the repaired layer
was restored to unflawed layer
quality (less than 0.2% porosity). This
The Defense Logistics Agency The two-year programme, which reportedly salvaged the part, and
(DLA), a combat support agency in includes partners, the Edison allowed acceptance (based on CT
the United States Department of Welding Institute (EWI) in Columbus, scan results) of a part that otherwise
Defense (DoD), has awarded a $1 Ohio, and OpenAdditive, the research would have been scrapped.
million contract to a team led by division of Universal Technology Under the programme, EWI is
Flightware Inc, headquartered in Corp. (UTC) in Dayton, Ohio, is using developing a large area profilometry
Guilford, Connecticut, USA, to extend a Layer Topographic Mapping (LTM) sensor to measure the entire
its work in developing an in-situ method to determine melt quality, bed of the AM machine with high
inspection method for metal Additive directly from as-formed layer precision. The sensor will reportedly
Manufacturing. surface measurements. be installed in UTC’s OpenAdditive
“DLA is actively applying the Under the initial effort, Flightware PANDA printer, a commercial, open
benefits of AM to better perform our demonstrated that the LTM in-situ architecture, Laser Powder Bed
mission supplying spare parts to the method can detect melt flaws, such Fusion (L-PBF) system. Flightware
warfighter,” stated, Denise Price, as lack of fusion, in real time on will then refine and improve in-situ
DLA’s Program Manager for the a layer-by-layer basis with 98.2% inspection algorithms to reliably
Small Business Innovation Program. detection rate and only 1% false determine layer quality of both the
“Flightware’s in-situ inspection detection. After detecting these as-formed melt and the powder bed
method can reduce scrap and improve flaw regions, appropriate repair www.dla.mil
yield, which reduces the cost and lead procedures were automatically www.ewi.org
time of parts made by AM methods.” defined and then performed, as a www.openadditive.com
OPTIMIZE YOUR PERFORMANCES

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APWorks and Additive Industries look

to series production of certified parts
APWorks GmbH, a subsidiary of tion of certified applications for the
Premium Aerotec, located at Airbus’ aerospace industry at a new Additive
headquarters in Taufkirchen, Industries Process & Application
Germany, and Additive Industries, Development Centre in Filton, near The MetalFAB1 system installed
Eindhoven, the Netherlands, are Bristol, UK. Daan Kersten, CEO of at APWorks, Taufkirchen facility
reported to be moving towards the Additive Industries, stated, “We are (Courtesy Additive Industries)
next phase of industrial Additive proud to continue our journey from
Manufacturing, namely the series prototyping to series production with number of parts that are additively
production of certified parts. APWorks, our first customer and one manufactured.”
APWorks was Additive Industries’ of the front-runners in our industry.” Andreas Nick, CTO of APWorks,
first customer, and has run “We believe metal Additive explained, “In the UK, our colleagues
extensive tests on its MetalFAB1 Manufacturing will continue to evolve headed by our Chief Product Officer
Beta system since its installation into a mature fabrication technology Jonathan Meyer will work closely
in March 2016, with its primary and prove to be able to compete with with the Additive Industries Process
focus being on the development and conventional processes like casting, & Application Development team
production of complex and advanced machining and Powder Metallurgy,” led by Dr Mark Beard, their Global
applications in industries such as commented Joachim Zettler, CEO Director for Process & Application
automotive, robotics and tooling, as of APWorks. “In the next years we Development, on further qualification
well as new material and software expect this market to continuously and certification of aerospace parts in
development. and rapidly grow, especially in the nickel based alloys like Inconel 718.”
Together, the companies will aerospace industry, new airplanes and www.apworks.de
collaborate on the series produc- aero-engines will contain a substantial www.additiveindustries.com
GPCMA / 174
Modified Atmosphere
Chamber Furnace
Laboratory Ovens and Furnaces for

CARBOLITE GERO manufactures laboratory and

industrial furnaces and ovens from 30 °C to 3000 °C.
The company has considerable experience in the
heat treatment of MIM parts and is a well-known
furnace supplier for additive manufacturing (AM) in
FORTHCOMING EVENT the field of powder metallurgy.
Adv. Engineering
Birmingham (30/10 – 31/10)
Formnext
Frankfurt (19/11 – 22/11)
www.carbolite-gero.com
Carbolite-Gero-Advert-GB-175x120-Metal.indd 1 25.09.2019 11:35:49
Centorr Vacuum Industries launches readily deteriorated in a binder-laden

environment.
two furnaces designed for sinter-based The Workhorse AM is Centorr
AM processes and heat treatment Vacuum Industries’ production

oriented offering specifically
designed for the secondary heat
Centorr Vacuum Industries, headquar- or Forming Gas depending on the treating, annealing, stress-relieving,
tered in Nashua, New Hampshire, USA, customer’s choice of binders. The all de-gassing, and quench cooling of
has announced the development of two graphite furnace hot zone is said to additivley manufactured parts. As
new furnace lines designed specifically offer a robust and inexpensive design laser-based AM processes may result
for Additive Manufacturing processes. for processing a variety of stainless in localised high-temperature melting
The company, an established supplier steel, tool steel, mild steels and alloy of small spots within the overall part,
of furnaces to the global Metal Injection materials. With a max temperature of micro-stresses can build up that need
Moulding (MIM)industry, has launched 1600°C the Sintervac is reported to be to be eliminated in order to achieve
the Sintervac AM and Workhorse AM able to process virtually all AM metals enhanced physical properties, such as
to meet the growing demand for metal on the market today. The graphite fatigue strength, hardness, durability,
Binder Jetting components. insulation is fabricated from durable and ductility. Annealing and stress-
The Sintervac AM furnace can rigid graphite board secured to a relieving in a vacuum or controlled
debind in both partial pressures or stainless steel jail with CFC hardware atmosphere of inert gas provides
positive pressures of Argon, Nitrogen, in lieu of carbon felt, said to be more that necessary furnace environment.
The ultra-clean vacuum environment
is also said to prevent oxidation,
offering improved surface finish
when compared to heat treatment in
common atmosphere box furnaces.
The Workhorse AM design
comprises of the standard hot zone
rated for 1315°C with an optional
upgrade to 1650°C for processing
higher melting materials such as
superalloys and Titanium. The furnace
chamber is frontloading, said to offer
better ergonomics and temperature
uniformity compared with vertical top/
Centorr’s new furnace is designed for processing additively manufactured parts bottom loaders or cylindrical hot zones.
(Courtesy Centorr Vacuum Industries) www.vacuum-furnaces.com
Midwest Prototyping announces Nate Schumacher, Director of

Strategic Partnerships at Midwest
AS9100 certification Prototyping, who oversaw both the
AS9100 Rev. D and ISO 9001:2015
Midwest Prototyping, LLC, a provider first independent Additive Manufac- implementations, commented,
of Additive Manufacturing services turing service bureau to achieve the “The AS9100D certification process
headquartered in Blue Mounds, ISO 9001:2015 Standard, the most examines our entire operation. From
Wisconsin, USA, has achieved AS9100 up-to-date version of the standard. the moment we quote a project
Rev. D certification – the standard of Steve Grundahl, president and or purchase raw material, to the
operational excellence required for founder of Midwest Prototyping, finished product and the way we ship
aviation and aerospace suppliers. stated, “By achieving the AS9100 an order, our customers can have
The certification means that the certification, we’ve opened up a new even more confidence in the quality
company is now able to manufacture avenue for digital manufacturing – we of our work.”
flight-ready components on all its AM can provide our technologies and Schumacher continued, “I’m
technologies. expertise directly to aviation and extremely proud of our team and
According to Midwest Prototyping, aerospace companies of all sizes. their efforts to bring our organisation
the AS9100 Rev. D certification builds We see this certification as a critical to the next level and the benefits this
onto its ISO 9001:2015 certified step forward to developing true digital programme brings to both Midwest
Quality Management System. In 2017, manufacturing solutions for our Prototyping and our customers.”
the company states that it became the customers.” www.midwestproto.com
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Nexxt Spine’s additively Cetim characterises new

manufactured spinal implant steel grade for Additive
receives FDA clearance Manufacturing
Nexxt Spine LLC, a medical device manufacturer based France’s Technical Centre for Mechanical Industry
in Noblesville, Indiana, USA, has reported that its Nexxt (Cetim) has released a new steel grade for the Laser
Matrixx® Stand Alone Cervical System, which was Powder Bed Fusion (L-PBF) Additive Manufacturing of
additively manufactured on a GE Additive Concept Laser parts which can reportedly undergo nitriding treatment.
Mlab system, has received FDA 510(k) clearance. According to Cetim, the new grade has been added to
The stand-alone anterior cervical interbody fusion the list of steels used in AM and the organisation has
system is intended for use as an adjunct to fusion at one characterised the 33CrMoV12 steel for the production
or two contiguous levels (C2-T1) in skeletally mature of parts via L-PBF Additive Manufacturing as part
patients for the treatment of degenerative disc disease. of its R&D work carried out on behalf of French
It is intended to be used with the bone screw fixation manufacturers.
provided and requires no additional fixation. The organisation stated that with its high carbon
“This enhancement of the Nexxt Matrixx portfolio was rate and nitriding capability, this steel offers attractive
the next natural progression for Nexxt Spine,” stated mechanical properties and opens up new application
Andy Elsbury, President, Nexxt Spine. “With patient care possibilities, especially in the power transmissions
always top of mind, we strive to develop end products that sector. It joins the three steels already commonly used
surgeons prefer and hardware patients can count on. Our for L-PBF manufacturing: X2CrNiMo17-12-2 (316L)
Stand Alone Cervical is no exception and will showcase and X5CrNiCuNb16-4 (17-4PH) stainless steels and the
the propensity of Nexxt Matrixx technology to facilitate X2NiCoMo18-9-5 steel (maraging 300).
the body’s natural power of cellular healing for fortified Cetim explained that although these three steels
fusion.” can be easily welded due to their low carbon levels
www.nexxtspine.com (approximately 0.05%), the same is not true for the
33CrMoV12 grade, which can have a carbon percentage
as high as 0.36%. Therefore, the powder for this type of
material must be pre-heated before L-PBF, making the
manufacturing process more troublesome.
Cetim believes that even though some AM systems
have a pre-heating system, in most cases the
pre-heating temperature is insufficient, being around
200°C and falling below the required 500°C. With a view
to limiting and possibly eliminating this operation, one
solution is to specifically determine the laser fusion
parameters.
The organisation’s study was carried out in
conjunction with Volum-e, a polymer and metal
prototyping and Additive Manufacturing specialist
located in à Blangy-sur-Bresle (Seine-Maritime,
France). By finely adjusting the parameters of the
process, the two partners state that they were able to
create test specimens and a demonstrator in the studied
steel by L-PBF.
Cetim reportedly continued the work by minutely
examining the parts including: chemical analysis of the
material, porosity rates, residual stresses, influence of
the heat treatment on the mechanical strength (tension
and bending), capacity for nitriding, fatigue strength,
etc. The organisation states that the assessment of this
study reveals that the steel 33CrMoV12, can be worked
by L-PBF exhibiting mechanical performance that is
higher than that of the same steel when laminated, and
due to its nitriding capability, its scope of use ranges to
heavily surface loaded parts.
www.cetim.fr
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Maltese mining group PRG to buy “The technology metals focus is

a perfect complement to PRG’s
Metalysis out of administration existing vertically-integrated
mining and refining operations and
Power Resources Group (PRG), a One of the challenges said to customer base,” PRG’s CEO, Ray
mining company headquartered in have been faced by Metalysis was Power, told Reuters.
Valletta, Malta, has announced that its reliance on externally sourced Metalysis grew out of research
it will buy Metalysis, Rotherham, UK, materials, the prices of which can at Cambridge University and has
after the company announced that it be volatile, for the metal powders it spent more than a decade devel-
had entered administration following produced for the Additive Manufac- oping technology for applications
financial difficulties in June 2019. turing industry. in the aerospace and automotive
Financial details of the transaction PRG mines tantalum and industry. Set up in 2001, it employed
were not disclosed but, according niobium in Rwanda, and has a sixty at two sites in Rotherham.
to Reuters, PRG would be the sole refinery in North Macedonia and Power stated that Metalysis had
owner of Metalysis. said that it is a good fit for Metalysis. reached industrial-scale production
only in the last nine months and
had been “just a whisper away from
commerciality” when it went into
administration.
The company has received a
total of £92 million ($114 million)
through numerous funding rounds,
most recently in 2018. It was
reported that Metalysis made
an operating loss of £7.1 million
($9 million) in the year ended
March 2018.
Eddie Williams of Grant
Thornton, joint administrator of
Metalysis, said the sale had been
“a very challenging process.”
Metalysis’ Discovery Centre on the Advanced Manufacturing Park in Rotherham www.metalysis.com
(Courtesy cloudinary.com) www.prgplc.eu
voestalpine sees impact of economic All four of the group’s divisions

were said to have seen a slight
slowdown and rising material costs decline in revenue, resulting mainly
from declining delivery volumes.
voestalpine Group, headquartered in in 2018. In addition to the cooling The start-up costs at the group’s
Linz, Austria, has reported its results economy and trade conflicts, a price automotive plant in Cartersville, USA,
for the first quarter of its fiscal year increase in iron ore and CO2 emis- were also said to have resulted in
2019/2020. The group stated that sion certificates were cited as the downward pressure on earnings in
the “macroeconomic environment main factors. the reporting period.
has clouded over significantly However, the company stated Herbert Eibensteiner, Chairman of
since the start of the business year that thanks to its broad product the Management Board of voestalpine
2019/20,” due to international trade portfolio it had succeeded, despite AG, stated, “The Management Board
conflicts and the associated, growing these challenges, in generating of voestalpine AG continues to work
weakness of the global economy, positive demand throughout key in a difficult environment, particularly
which strongly affects Europe’s customer segments such as rail with respect to the development of ore
export-oriented industries, and the technology, aerospace, warehouse and steel prices, on achieving EBITDA
automotive industry in particular. and welding technology. In addition, for the current business year that is
The company reported €3.3 it stated that it was already working comparable to that of the previous
billion revenue for Q1 2019/20, down on counteracting market pressures business year even though the
3.8% from the previous year (€3.5 through cost and efficiency uncertainties have mounted since the
billion). Net profit was reported at improvement programmes across start of the current business year.”
€90 million, down from €226 million the group. www.voestalpine.com
Industry News
Enhanced powders
to achieve
higher performances
Visit us at
formnext
www.mimete.com
19-22 November 2019 - Frankfurt

Hall: 12.1 Booth: F119
Industry News
AM METAL POWDER
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ExOne licenses method

for AM of boron carbide
from Oak Ridge National
Laboratory
The ExOne Company, North Huntingdon, Pennsylvania,
USA, has reported that it has licensed a patent-pending
method of additively manufacturing aluminium-
infiltrated boron carbide (B4C) collimators and other
components used in neutron imaging from Oak Ridge
National Laboratory (ORNL), Oak Ridge, Tennessee,
USA.
Following the announcement of their collaboration
project, researchers at ORNL developed the Additive
Manufacturing method on the ExOne M-Flex®, a metal
AM system that uses Binder Jetting technology to
produce additively manufactured objects in stainless
steel, bronze or tungsten, as well as sand, ceramics and
composites.
The ORNL team, led by David C Anderson, Group
Leader of Instrument Engineering, developed a process
to additively manufacture objects in B4C, a neutron-
absorbing material, and then infiltrate the objects with
aluminium. The final aluminium-infiltrated B4C material
is known as a metal-matrix composite (MMC), a type
of cermet. ORNL’s Amy Elliott and Bianca Haberl are
co-inventors of the process.
According to ORNL, the development is significant
because aluminium-infused B4C has strong but Particle Size & Shape
lightweight properties, as well as energy-absorbing
characteristics that are useful in neutron scattering Analysis of Metal Powders
instruments, which enable researchers to capture data
down to the atomic level.
ExOne states that it plans to use the licence to
commercialise the AM production of aluminium- CAMSIZER M1 & CAMSIZER X2 – new
infiltrated B4C objects, such as shielding equipment and generation optical particle analyzers based on
components used in neutron scattering instrumentation. Static and Dynamic Image Analysis.
Dan Brunermer, Technical Fellow at the ExOne
Company, commented, “It delivers results that X-rays
n Particle size and shape analysis down to
can’t. Neutrons can detect light elements, like hydrogen
or water, but they also penetrate through heavy the low micrometer range
elements like lead, which enables analysis of complex n Reliable detection of defective particles like
processes in-situ.” satellites or fused beads
The intellectual property covered in the licence
agreement includes pending U.S. patent application no. n Evaluation of individual particles with
16/155,134, titled ‘Collimators and Other Components X-Plorer software module
from Neutron Absorbing Materials Using Additive
n Dry and wet measurement possible
Manufacturing,’ as well as two additional provisional
filings. Under the agreement, ExOne will also engage
in ongoing AM production of a variety of B4C matrix
components used in neutron scattering experiments at
ORNL.
Visit us at Stand 11.0 - B51
www.exone.com
www.ornl.gov
www.retsch-technology.com
Vol. 5 No. 3 © 2019 Inovar Communications Ltd Metal Additive Manufacturing | Autumn/Fall 2019
RT-Advert-GB-MetalAM-formnext-90x255.indd 1 53
09.09.2019 11:22:26
Incus to reveal novel metal AM process 40–100 µm. With the new Incus
process, it is possible to use metal
based on photopolymerisation powders down to 20 µm at competi-
tive build speeds.
Incus GmbH, a new metal Additive and offers reproducibility without Mitteramskogler further added,
Manufacturing machine maker based elaborate process parameters. “With our new printer series, it is not
in Vienna, Austria, will debut its The company evolved from ceramic only possible to produce very small
novel metal AM system at Formnext AM specialist Lithoz GmbH. “Our complex components with the finest
2019 this November. The company's goal is to become an integral part surface structure, it also allows us
Hammer Series machine uses a of production in the metal industry. to use new metal powder mixtures,
technology based on the principle of To achieve this, we are focusing on such as non-weldable powders. In
photopolymerisation for the Additive absolute service orientation and our material development projects with
Manufacturing of intricate metal passion for bringing innovative metal our customers, we have already
components. printing solutions to market. Quality shown that we can achieve similar
This new metal AM technology and partnership are cornerstones material properties compared to
is said to combine excellent surface of our business model," stated Dr Metal Injection Moulding, a mass
aesthetics for fine structures with Gerald Mitteramskogler, CEO of production process for metal parts.
cost-efficiency, reproducibility and Incus. We are always happy to take on
increased manufacturing speed. The According to Incus, metal Additive challenges concerning new mate-
process uses a feedstock which is Manufacturing technologies currently rials or geometries to benchmark
said to increase working environment on the market offer the production our process.”
safety, eliminate the need to invest in of parts using relatively coarse metal Two beta machines are reported
protective gas atmosphere solutions, powders in the range of around to have been in use for development
for over a year, and feasibility
studies have shown that the expec-
tations for the technology are being
met. Prof Carlo Burkhardt, Head of
the Institute for Strategic Technology
and Precious Metals at the Univer-
sity of Pforzheim and founder of
local company MetShape, who has
been involved in the development of
applications for the new systems,
stated, “We are always intrigued by
cutting-edge technologies and are
convinced that we are part of a new
era in the metalworking industry.
The components we produced in
the beta phase with the printer
exceeded our expectations."
Gerald Mitteramskogler, CEO of Incus (left) hands over the first Hammer AM Ventures, known for strategi-
system to Professor Carlo Burkhardt, founder of MetShape (Courtesy Incus) cally sustainable investments in
advanced manufacturing technolo-
gies, especially Additive Manufac-
turing, is backing the company.
Johann Oberhofer, Chief Technology
Officer of AM Ventures, commented,
“When the project was presented
to us, we saw immediately that this
was not a small boost to innovation.
We believe that this new technology
will open up many opportunities in
the metal industry and we want to
help make this happen.”
Incus will exhibit the Hammer
Series at Stand D32 in Hall 11.1 at
First components produced with the Incus Hammer series (Courtesy Formnext.
MetShape/Incus) www.incus3d.com
Pusher Furnaces and
Vacuum Furnaces
for Debind and High Temperature
Sinter of Binder Jet 3D Printed
Components
Atmosphere and Vacuum Annealing

furnaces for Annealing/Stress
Relieving of Selective Laser Melted,
Selective Laser Sintered, and Direct
Metal Laser Sintered Components
814.834.2200
Sinterite-Hayes@gasbarre.com
THERMAL PROCESSING SYSTEMS
310 State Street
St. Marys, PA 15857
www.gasbarre.com
MPP Ltd
PM Solutions by Design Materialise invests in Engimplan to drive
introduction of AM implants in Brazil
Materialise, the Additive Manufacturing as they understand the positive
solutions company headquartered impact of personalised implants
in Leuven, Belgium, has invested in and patient-specific solutions on
MPP Ltd manufactures
Engimplan Implants Engineering, surgical outcomes,” stated Brigitte
a manufacturer of orthopaedic and de Vet, Vice President and General
both large and
cranio-maxillofacial (CMF) implants
small lots,
Manager of Materialise Medical.
MPP Ltd - your Partner in
and instruments baseddelivering
in Rio Claro, powders in
“With this investment, we will expand
metal powder processing
Brazil, to accelerate thequantities
introduction of as
ourlow asproduct
medical 5kg and service
Ÿ Powders tailored to your additively manufactured, through
personalisedto multi-tonnage
portfolio, confirming our commit-
requirements implants and instruments orders.
into the ment to strengthen our position
Brazilian market. and grow our global presence in the
According to Materialise, it has medical industry.”
Ÿ Clean, spherical powders signed an agreement to acquire a José Tadeu Leme, CEO of
75% stake in Engimplan through a Engimplan, commented, “This
Ÿ Flexible - R&D to combined acquisition of existing and investment by Materialise sends
production new shares via its Brazilian subsidiary a strong signal to our customers
Engimplan Holding Ltda. As part of and the industry that we remain
the transaction, Materialise will gain committed to developing our innova-
Ÿ Optimised for AM
access to Engimplan’s local productive solutions that improve the lives
tion facility, expand the company’s of many people, and that we have the
portfolio with its experience, and enter confidence and support of a pioneer
its existing partner and distribution and global leader in 3D printing.
network in Brazil. The closing of the Together, we can introduce new
transaction is expected to take place levels of innovation in the develop-
in August. ment of personalised implants in
“Surgical planning and 3D Brazil.”
printing are increasingly adopted www.materialise.com
by orthopaedic and CMF surgeons, www.engimplan.com.br
Gefertec to open its first US

manufacturing facility in Virginia
Please contact us to discuss your Gefertec, LLC, the US division cost of two years of temporary space
requirements for customised of metal Additive Manufacturing at IALR.
powder development for both company Gefertec GmbH, Berlin, “Gefertec is excited to announce the
R&D and large scale production Germany, is to open its first US facility opening of our Danville – Pittsylvania
in Danville, Virginia, USA. The new County location as our first US location
Application of MPP Powders manufacturing facility will initially for our 3DMP Additive Manufacturing
be based at Danville’s Institute for business,” stated Andrea Clark,
Advanced Learning and Research President of Gefertec, LLC.
Ÿ Automotive (IALR), before moving to a permanent Tobias Roehrich, CEO of Gefertec
Ÿ Aerospace
space in Virginia’s Danville/Pittsyl- GmbH, added, “This is in alignment
Ÿ Energy Storage
vania County area in future. with our long-term commitment
Ÿ Energy Generation
The establishment of the new to Danville and the Institute for
Ÿ Medical
facility will involve an investment Advanced Learning and Research
of $1.9 million, and is receiving and we are excited to expand our
Metal Powder & Process Limited support from the Tobacco Region business to the US. Danville has been
Chaucer Business Park - Dittons Road Revitalization Commission with a chosen for its excellent business and
Polegate - East Sussex - BN26 6JF - UK $45,000 Tobacco Region Opportunity community support and its involve-
Tel: +44 (0)1323 404 844 Fund (TROF) grant, while the Danville ment in the advanced manufacturing
info@metalpowderprocess.co.uk Pittsylvania Regional Industrial sector.”
www.metalpowderprocess.co.uk
Facility Authority (RIFA) will cover the www.gefertec.de
Industry News
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Physna completes Series A funding

round with investment by Drive Capital
Physna, a technology startup head- user’s own database of 3D files, and
quartered in Cincinnati, Ohio, USA, the results can include similarities
has completed a $6.9 million Series and differences between 3D models
A round of financing led by venture returned by the search engine and the
capital firm Drive Capital, Columbus, files used for the search, regardless of
Ohio, USA. Physna states that it will file types. The search is said to allow
use the funding to continue its software users to search millions of 3D models Physna has built a geometric search
product development, increase in seconds. engine that can increase efficiencies
adoption of its technology, and expand “The results are orders of magni- within CAD design and manufacturing
its engineering and sales teams. tude more accurate and faster than (Courtesy Physna)
The company reports that it has was ever previously possible in 3D
built a geometric search engine that search,” stated Paul Powers, Founder
can increase efficiencies within CAD and CEO of Physna. “We are just “Drive Capital matches our passion
design and manufacturing by breaking scratching the surface. The uses for for taking on major issues and
down 3D files into a codified structure. Physna’s core technology are virtually fixing large, fundamental problems
Physna explains that this approach limitless.” through groundbreaking technology,”
creates a ‘DNA-like’ structure Mark Kvamme, Drive Capital added Powers. “We are excited for
representative of the 3D model, and Partner, commented, “We are very Mark to join our board. We know the
that through machine learning, the excited for the opportunity to invest partnership with Drive will allow us
search engine can recognise common in Physna. We believe what Paul and to accelerate our development and
traits. his team are doing in search has the growth.”
According to Physna, results from potential to revolutionise the work- www.physna.com
its search engine are pulled from a flows of engineers around the world.” www.drivecapital.com
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Collaborative project to look

at Additive Manufacturing of OXMET
hardmetals TECHNOLOGIES
A new collaborative project on the Additive Manufacturing
ADDITIVE MANUFACTURING METALLURGY
alloy design • microstructure optimisation • rapid production and testing
of hardmetals is now reported to be open for participation.
The AddiHM Project is set to establish the benchmarking of
Oxmet Technologies
three non-laser based AM processes for the production of
homogeneous WC-12Co hardmetal blanks.
The AddiHM project is coordinated by OCSynergies
along with Fraunhofer IKTS Dresden, the Katholieke
Universiteit KU Leuven, TECNALIA Research & Innovation
San Sebastian and the Technical University of Catalonia
BETTER ALLOYS
BarcelonaTech UPC. The aim is to establish a comparison
Alloys-by-Design computational development platform
of Fused Filament Fabrication (undertaken at IKTS), metal
Binder Jetting (at Tecnalia) and direct ink writing (at KU library of high-performance proprietary alloys for AM
Leuven). An evaluation of the final AM components will be
also carried out at UPC. BETTER ALLOY COMPONENTS
It is stated that the AddiHM project will last twelve
Bespoke alloy sourcing • Additive manufacturing • Heat
months and is now open for participation to all interested
treatment optimisation • Machining and EDM • Design •
organisations. The total budget of the project is €69,900 Sample preparation • Rapid characterisation
to be shared by a minimum of six funding participants.The
project will be conducted in memory of Dr Leo Prakash,
who passed away in February 2019 aged sixty-nine,
Nickel superalloy ABD®-900AM on sale now
and who first conceived the idea for the project. Those
• Excellent printability – crack-free with wide processing window
interested in joining the AddiHM project or who wish to
• Very high strength and creep resistance 200°C above Alloy 718
receive more information are invited to contact Dr Olivier
Coube (olivier.coube@ocssynergies.com).
www.ocsynergies.com/projects
Aeromet’s A20X metal

powder for AM surpasses
500 MPa UTS mark
Aeromet International Ltd, headquartered in Worcester,
England, UK, reports that its patented A20X™ powder, an
aluminium alloy for Additive Manufacturing, has surpassed
the key 500 MPa Ultimate Tensile Strength (UTS) mark as
part of its research project, HighSAP.
The HighSAP project is supported by the UK’s National
Aerospace Technology Exploitation Programme (NATEP),
and led by Aeromet with collaboration from Rolls-Royce,
Renishaw and Phoenix Scientific Industries (PSI). Aeromet
states that the heat-treated parts produced using A20X
achieved a UTS of 511 MPa, a yield strength of 440 MPa
and elongation of 13%.
Mike Bond, Director of Advanced Material Technology
at Aeromet, commented, “Since bringing the A20X alloy to
market for Additive Manufacturing five years ago, we have
seen significant adoption for high-strength, design-critical
applications. By working with Rolls-Royce, Renishaw and
Catch us at Formnext 19-22 November Stand 12.0-B81E
PSI we have optimised processing parameters that led to
record-breaking results, opening up new design possibili- oxmet-technologies.com
ties for aerospace and advanced engineering applications.” sales@oxmet-technologies.com | +44 1865 954 250
www.aeromet.co.uk
BASF expands reach of its Ultrafuse 316L industrial-grade materials. We are

proud to announce that print profiles
metal filament for Ultrafuse 316L will be added to the
Ultimaker Marketplace,” added Paul
BASF 3D Printing Solutions GmbH, the Additive Manufacturing of metal Heiden, Senior Vice President Product
Heidelberg, Germany, has announced parts considerably easier, cheaper, Management, Ultimaker. “3D printing
it is working with iGo3D (Germany), faster and accessible to everyone.” professionals worldwide can then use
Ultimaker (the Netherlands) and Athanassios Kotrotsios, Managing FFF technology to produce functional
MatterHackers (USA) to commercialise Director of iGo3D added, “To reach the metal parts at significantly reduced
its Ultrafuse 316L filament, a metal- full potential of the metal filament and time and costs.”
polymer composite designed for use to ensure a solid start, it is necessary The metal composite filament is
in Fused Filament Fabrication (FFF) to understand that Ultrafuse 316L is highly flexible and strong, allowing
Additive Manufacturing systems. not a conventional filament. Our goal it to be used with both Bowden and
Ultrafuse 316L is said to enable is it to provide full service packages direct drive extruders, as well as being
simple and cost-efficient production and support from the first request guided through complex filament
of fully metal parts for prototypes, up to the finalised and sintered part, transport systems.
metal tooling and functional metal to implement metal 3D printing as a “Ultrafuse 316L from BASF enables
parts. Once formed, parts are debound natural component in your manufac- engineers and designers to produce
and sintered to achieve a final 316L turing process.” true, pure, industrial grade metal
stainless steel part. Using metal powder within a binder parts easily and affordably using
“Ultrafuse 316L can, under certain matrix is said to dramatically reduce desktop 3D printers,” stated Dave
conditions, be processed on any the potential hazards of handling the Gaylord, Head of Products, Matter-
conventional, open-material FFF fine metal powders used in alternative Hackers. “This material is a significant
printer,” explained François Minec, powder based AM processes. technological advancement and truly
Managing Director, BASF 3D Printing “The Ultimaker S5 raises the bar for a shift in how we describe what is
Solutions. “Our goal was to develop a professional 3D printing by offering a possible with desktop 3D printers.”
high-quality metal filament that makes hassle free 3D printing experience with www.basf-3dps.com
Sigma Labs Inc.

3900 Paseo del Sol
Santa Fe, NM 87507
+1 (505) 438-2576 HALL 12.0
www.sigmalabsinc.com BOOTH E49
Checkmate.
HN OL
EC O
T
G
H
IE
DS
S
CE
RS
L
A
B
E
R Y
AT
IN G 20
Elnik began 50 years ago manufacturing parts for furnaces, molding machines, etc. And for the past 25 years,
Elnik has been leading the field of Batch Debinding and Sintering equipment since our entry in the mid 1990’s.
Add onto that our 20 year partnership with DSH Technologies, our innovation keeps us at the cutting edge with
products that work due to extensive in house testing. We also service our equipment with a well-trained and
energetic service team. This dedication and excellence in customer service allows Elnik and DSH Technologies
to be the only partners you will ever need for the MIM and Metal Additive manufacturing process.
107 Commerce Road I Cedar Grove, NJ 07009 USA I +1 973.239.6066 I elnik.com I dshtech.com
Electric motor housing with integrated

cooling for Formula Student racing team
JAMPT Corporation, Miyagi, Japan, in length. The housing also required
has been working with the Technical a sufficient cooling system to transfer
University of Munich’s TUfast Racing heat induced by stator losses and to
Team to develop an electric motor avoid overheating, which would lead
housing with integrated cooling for to its automatic shut down.
use on its Formula Student electric- To address this need, the team and
powered racing car. Thanks to the JAMPT opted for an integrated water
use of metal Additive Manufacturing, cooling system consisting of a ‘pin’
JAMPT and the TUfast team optimised structure, incorporating 45° angled
the design of the housing and inlet pins, enabling the surface to transfer
to produce a motor which allowed more heat due to the increased
the vehicle to remain aerodynamic, surface area. The resulting turbulent
which was lightweight, and which had flow of coolant also maximises heat
sufficient power and torque. transport, with the pin structure The inlet and outlet were separated
The annual Formula SAE and offering reduced flow separation and from the main body for the build
Formula Student competitions a lower pressure drop compared to a process in order to reduce the need
challenge students to design and helix structure. for support structures (Courtesy
build race cars, which race and are The only manufacturing method JAMPT Corporation, TUfast)
also ranked based on their design, capable of producing a part with this
acceleration, efficiency, endurance type of inner structure in one piece
and cost, among other factors. The is metal Additive Manufacturing. the need for support structures within
2019 competition required the TUfast JAMPT produced the housing by the cooling channel, and ensured
team to produce two all-new Formula Laser Powder Bed Fusion (L-PBF) that no metal powder was left inside
Student racing cars, one with an on an EOS M 280 system, followed the cooling channels after the build.
electric and one with a combustion by milling and turning to achieve To reduce the need for support
powertrain. the final tolerances. The housing structures at the front surface of the
In order to fit completely into the was built from AlSi10Mg due to the part, the inlet and outlet were also
wheel rim of the vehicle to minimise material’s low density and weight, separated from the main body for the
drag, the electric motor housing high heat conductivity and low cost. build process.
developed in conjunction with JAMPT The optimised design of the To further save weight, a titanium
– which is also one of the team internal structure made it possible hollow shaft was used in the motor
sponsors – had to be under 150 mm to produce the part by L-PBF without design. A polygon connection was
used between the rotor shaft and
sun gear to reduce the length and
lower weight. Axial length was kept
as low as possible to fit the motor
completely into the rim, and a carbon
fibre-reinforced polymer (CFRP) cap
was fitted for the HV-connection to
avoid collisions with the tie-rod.
Since the launch of the Formula
Student 2019 competition, the
TUfast team has competed in two
races in the electric race car in
which the cooling shell and inlet are
installed – Zala Zone, Hungary and
Red Bull Ring, Austria – winning both.
TUfast recently competed and took
first place in the biggest event on
the Formula Student circuit, at the
Hockenheimring, Germany, which ran
in August 2019.
CFD simulation (left) was used to optimise the cooling structure. The splitter at www.jampt.jp/en
inlet offered better flow distribution (Courtesy JAMPT Corporation) www.tufast.de
Visit us
Visit Formnext
atusFormnext
atVisit
us at Formnext
Hall 12.0
Hall Hall
12.0
Booth:
12.0
Booth:
A121
Booth:
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Laser
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hothot
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VDM Metals
offers range of
metal powders
for Additive
Manufacturing
VDM Metals GmbH, headquartered
in Werdohl, Germany, is a global
supplier of metals offering a range
VDM Metals offers a range of metal powders for Additive Manufacturing
of metal powders for Additive
(Courtesy VDM Metals GmbH)
Manufacturing. Its product portfolio
includes cobalt-chrome alloys,
corrosion resistant alloys, superalloys euros in its powder production plant, VDM Metals produces powders
and special stainless steels, as well among other areas. from proven alloys and also
as manufacturing custom alloys The company uses a vacuum optimises conventional materials
developed in collaboration with its inert gas atomisation (VIGA) process for the powder production process.
customers. to manufacture its range of metal The high-purity metal powder is
VDM installed its metal powder powder products. The standardised produced by means of vacuum
manufacturing plant at its Unna, production method allows VDM induction melting followed by inert
Germany, facility in 2017, following Metals to offer a wide variety of gas atomisation, with the individual
the construction of a new hall particle sizes and particle size steps precisely coordinated to
specifically for powder production. distributions particularly suited ensure the composition and purity of
Earlier this year it announced a to metal Additive Manufacturing the powder.
further investment of several million systems. www.vdm-metals.com
VACUUM FURNACES FOR POST ADDITIVE MANUFACTURING

info@tmvacuum.com +1-856-829-2000 www.tmvacuum.com
T-M Vacuum Products, Inc.

Cinnaminson, NJ
Perfect choice for stress relieving,

solution treatment, ageing, sintering,
brazing or other thermal processes
All metal hot zones
High vacuum, bright and shiny
Integrated quick cool
Controlled atmosphere
±3°C uniformity
Sizes from 0.25 to 16ft3 (7-453l)
Work loads from 50 to 1,600lbs (23-726kgs)
Operating pressure 10-6 torr to 6 bar Super Series High Vacuum Furnace
AM Powder Plus network for HALL 11.0 | STAND F65
efficient parts and powder

handling
SS-PREP
SS-PREP
Assonic Dorstener Siebtechnik GmbH, Solukon
Maschinenbau GmbH and ULT AG have announced the SphericalPowder
Spherical Powder
formation of a network, AM Powder Plus (AMP+), which will
offer integrated solutions for highly automated parts and Ti6Al4V ELI, BT20, Ti6242,Ti1023
powder processing and handling in the Laser Powder Bed
★★
Ti6Al4V ELI, BT20, Ti6242,Ti1023
Fusion (L-PBF) Additive Manufacturing process. ★★ Inconel
Inconel 718,
718, 625625
This includes the collection, sifting, reprocessing and 316L, 17-4PH, A100, Duplex
drying of surplus powder, with automated component ★★
316L, 17-4PH, A100, Duplex
removal and depowdering for clean transfer to post- ★★ Co-Cr-W,
Co-Cr-W, Co-Cr-Mo,
Co-Cr-Mo, CrCrWMo
CrCrWMo
processing. Unexposed powder can then be returned in
a fully processable state, assuring occupational health
and safety, dust explosion protection, and a clean working
environment.
The AMP+ partners will reportedly pool their combined
knowledge and experience in AM to offer these solutions to
the industry. In practice, they stated that they have encoun-
tered blind spots in the L-PBF process chain that have so far
prevented industrial users from making widespread use of
this new technology. These shortcomings are concentrated
on a comparatively short section of the process, between the
completion of the build and the start of post-processing.
Currently, this blind spot results in a need for companies
to conduct inefficient manual steps and consume unneces-
sarily high quantities of powder, the network stated. In
addition, the challenge of avoiding explosion hazards and
of airborne pollutants must be met for AM to truly succeed.
AMP+ believes that its solutions can address each of these
problems. WireAdditive
Wire Additive
The AMP+ network will exhibit for the first time at this
year’s formnext, November 19-22, Frankfurt, Germany.
★★ Ti6Al4V
Ti6Al4V ELI,
ELI, BT20,Ti1023
BT20,Ti1023
www.ampplus.de
★★ 0.8/1.2/1.6/2.0
0.8/1.2/1.6/2.0 diameter
diameter
★★ One
One barrel
barrel with
with 100-300kg
100-300kg
AddUp and IPC form One
One Spool
Spool with
with 10-25kg
10-25kg
Addilys for metal Additive
Manufacturing in tooling
France’s AddUp Group and Plastics and Composites Manu-
facturing Technical Centre (IPC), have formed Addilys, a joint
platform focused on driving the adoption and deployment
of metal Additive Manufacturing in the area of tooling and
plastics processing. The new entity will be headquartered
near to AddUp and IPC’s headquarters.
The goal of the platform is to provide manufacturers with
global solutions, from advice to maintenance, as well as
tooling design, demonstrations and manufacturing services.
The partnership is expected to make it easier for companies
to deploy customised and optimised thermal solutions,
particularly in industrial-level plastics processing, through
the use of the conformal cooling solutions made possible by AS9100D ISO 13485
AS9100D ISO 13485 www.c-semt.com
www.c-semt.com
metal AM. gt@c-semt.com
gt@c-semt.com
www.addilys.com | www.addupsolutions.com
thyssenkrupp predicts $100

billion economic value for
AM in ASEAN by 2030
thyssenkrupp AG, Essen, Germany, has published a
white paper on the potential of Additive Manufacturing
in the Association of Southeast Asian Nations (ASEAN)
region, based on research undertaken by the company,
with the support of partners in Singapore, as a prelude
to the official launch of its AM TechCenter Hub in
Singapore. Titled ‘Additive Manufacturing: Adding Up
Growth Opportunities for ASEAN’, the white paper looks
at the state of AM in the ten member countries.
AM penetration in ASEAN is currently quite
–22, 2019
xl 1t1.1, Booth C18

ber 19 small, accounting for only 5–7% of Asia’s total AM
e
Novem (Main)
n
rt
spend (estimated at $3.8 billion) for 2019. However,
m
Fran k fu
r
fo e visit us: Hal thyssenkrupp’s report states that there is huge potential
for the ASEAN market given its contribution to the global
Pleas manufacturing output. Manufacturing accounts for 20%
of the region’s GDP, employs nearly 50 million of its
workforce and is expected to experience major growth in
the near future.
The report predicted that Additive Manufacturing
Materials Services will generate around $100 billion of incremental value
Powder metals
by 2025, impacting ASEAN’s projected real GDP by 1.5
to 2%. Opportunities presented by AM are expected
to enable a reduction of ASEAN’s import dependence,
for additive with the potential to impact at least $30–50 billion by

localising manufacturing closer to consumption and
manufacturing
reducing overall import dependence by up to 2% for the
region
AM can also contribute in sustainable development
and improve ASEAN’s competitiveness in already
Metal powder – supplied worldwide for established global value chains across key sectors
such as automotive, electronics, and chemicals, as
almost all applications.
well as accelerate the region’s growth in industries like
Metal additive manufacturing of components has aerospace, medical devices, and healthcare. It is believed
been developed into a series production process. that Additive Manufacturing would enable the ASEAN
The demand for powders are increasing rapidly which region to further advance its Industry 4.0 and skills
is where we come in: With our high-quality metal development focus, and promote local entrepreneurship
powders you can improve your production process with the potential to create 3–4 million additional AM
and your profitability. jobs for the region by 2030.
Contact us for a competitive quote. “As our study shows, Additive Manufacturing delivers
enormous potential to transform the ASEAN region
thyssenkrupp Materials Trading GmbH
and level up vital sectors,” stated Jan Lueder, CEO of
Rellinghauser Str. 3, 45128 Essen, Germany
NE-PM.tkmat@thyssenkrupp.com thyssenkrupp Regional Headquarters Asia-Pacific.
www.thyssenkrupp-materials-trading.com “Additive Manufacturing will surely be an innovative
solution to further drive growth in ASEAN, as long
as stakeholders work together to continue building
awareness as well as a supportive ecosystem for
Additive Manufacturing adoption and development. We
have found such an ecosystem in Singapore, and that is
one of the key reasons in establishing our first Additive
Manufacturing TechCenter Hub outside of Germany.”
www.thyssenkrupp.com
68 Metal Additive Manufacturing | Autumn/Fall23.09.19

Anz_PowderMetals_90x255_GB_Messe-RZ.indd 1 2019 14:52 © 2019 Inovar Communications Ltd Vol. 5 No. 3
Farsoon and Next Chapter

Manufacturing develop H13
components with conformal
cooling
Farsoon Technologies, headquartered in Hunan,
The lifter design with a conformal cooling circuit (Cour-
China, has collaborated with its partner Next Chapter
tesy Farsoon Technologies/Next Chapter Manufacturing)
Manufacturing (NXCMFG), Grand Rapids, Michigan,
USA, to develop advanced process parameters for
the production of robust H13 tool steel components
using Laser Powder Bed Fusion (L-PBF) Additive Farsoon and NXCMFG have partnered to find a
Manufacturing. H13 tool steel is used for more hot work solution for these challenges. A number of tests have
tooling applications than other grades of tool steel, as reportedly been conducted by Farsoon’s application team
well as in a variety of cold work conditions, because of its to develop processing parameters for the manufacture
high toughness and good stability. of parts in H13, considering factors such as the optimal
H13 is suited to a range of applications, from die laser power, scanning strategies, stress relief and heat
casting, extrusion dies and highly tough and polished (up treatment.
to A1 grade) injection moulding components. However, its Farsoon reports that its optimised parameter set
high carbon content makes it difficult to weld or process helps to eliminate the thermal cracks which may develop
using standard L-PBF parameters, as the carbon content when welding H13 steel and delivers a high relative
is easily vapourised and can contaminate the powder density of over 99%. The additively manufactured H13
surface during the melting process – potentially leading parts achieved in the project are also said to exhibit
to issues such as internal flaws, porosity and thermal excellent mechanical properties in comparison to
cracks. wrought H13 material.
One successful H13 component which the partners
have recently developed is a lifter used to cool and
separate plastic parts from the core during the injection
moulding process. A conformal water circuit design was
added to the geometry of the lifter, and the component
Metal Powder was additively Manufactured on a Farsoon FS271M
Recovery System. system. Next Chapter Manufacturing stated that it was

able to deliver four replacement lifters in eight days.
Convey, Screen, The company states that these lifters can be installed
Recover & Reuse directly in the production line, with the new conformal
water circuit helping to accelerate the cooling process
Additive Manufacturing Metal and eliminate warpage in finished injection moulded
Powder Recovery System
(AM-MPRS) Conveys, Screens,
parts. The optimised lifters are said to have improved
Recovers & Reuses Metal Powders production volume when using the original factory
including Inconel, Stainless Steel, settings, reducing the cycle time from 48 seconds to 30
Haynes 282 and Cobalt Chrome. seconds and achieving a reported annual saving of over
Cuts Metal Powder $100,000.
Recovery Time by 85%! “We decided to partner with Farsoon Technologies
because its system is open, which means we can develop
Let us solve your material
specific processes that enable us to print H13 and other
handling challenges. Visit
tool steels efficiently,” stated Jason Murphy, President of
vac-u-max.com/AM-MPRS
Next Chapter Manufacturing.
and fill out RFQ!
“This open parameter system also enables us to do
test builds and refine our process to improve robustness
Stand 12.0-A111 and speed further,” he continued. “The technology of the
Farsoon machine gives designers a significant amount of
additional freedom to provide the most efficient designs
for Additive Manufacturing, which other machines do not
offer.”
http://en.farsoon.com/
www.nxcmfg.com
www.vac-u-max.com (800) VAC-U-MAX
Innovar_2019_3.54331x4.92126-MetalAM.indd 1 8/4/2019 6:20:42 PM

Industry News
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World’s lightest cycle gear wheel

additively manufactured and tested by
Tour de France racers
CeramicSpeed, Holstebro, Denmark, CeramicSpeed states that its R&D
and the Danish Technological Institute department have been testing the
(DTI) in Taastrup, have collaborated to wear on the additively manufactured
additively manufacture a lightweight titanium parts, which proved to be
titanium pulley wheel for a race-bike more durable and suitable for corro-
gearing system, aimed at professional sion resistance and strength at low
cyclists. The radical new design, density than conventional aluminium
reported to be the world’s lightest gear parts.
wheel, was race-condition tested by To offer serial production of
competitors from this year’s Tour de a high-quality, additively manu-
France. factured product, it is stated that
The pulleys, manufactured on SLM the entire process chain must be
Solutions’ SLM®500 metal AM system, coordinated. The process begins
are equipped with seventeen spokes with the component redesign for
with a diameter of 2 mm and a wall the additive process, in this case
thickness of only 0.4 mm. Due to the a delicate mix of not changing the
hollow design, it has been possible customer’s design, while adding
to reduce the total weiaght of the material for surfaces that require
sprocket to just 8.4 g. CNC machining, optimising support,
“The hollow geometry of the objects and minimising wall thickness and
cannot be produced with conventional weight. After successful production,
methods, and the 3D printing in the equally challenging, yet important
combination with subsequent special- post-processing steps take place,
ised processes leads to a unique where the Danish Technological
innovative product,” stated Thor Institute uses its entire range of Only assembly is required when the
Bramsen, Industrialisation Manager manufacturing knowledge, ensuring finished product is delivered (Courtesy
at the Danish Technological Institute. that only assembly is required when SLM Solutions)
Despite the complex geometry, DTI is the finished product is delivered.
able to reliably build the same quality “3D printing technology has given
parts in series production. us a lot of leeway to experiment creatively with design, while at the
same time being able to optimise
a product’s function,” commented,
Carsten Ebbesen, R&D Manager at
CeramicSpeed. “The collaboration
with DTI has led us to develop and
produce gears in a radically new
design form that is only possible with
3D printing.”
The first ceramic bearings from
CeramicSpeed were introduced to
the Tour de France less than twenty
years ago. Thanks to the design
provided by Selective Laser Melting,
and its partnership with the DTI, the
company continues to develop cycling
technology and is helping set new
standards as riders test the latest
innovations in their training to be the
next to debut new advancements at
future Tour de France races.
www.slm-solutions.com
The additively manufactured titanium pulley wheel produced by CeramicSpeed www.ceramicspeed.com
and DTI (Courtesy SLM Solutions) www.dti.dk
Siemens to lead IDEA project for A development and implementa-

tion phase will be followed by a
industrial AM in Germany validation process in the second
half of the project. This will involve
Siemens has taken over the role of Industries; machine makers EOS measuring how well IDEA’s targets
project management for the German and Trumpf; and AM users Liebherr- have been achieved based on
Ministry of Education and Research Aerospace, MBFZ toolcraft GmbH, manufacturing demonstrator
grant project IDEA (Industrial MTU Aero Engines, and Siemens Gas components in two pilot lines.
implementation of Digital Engineering and Power. The project is supported The prototypes for industrial
and Additive Manufacturing). The by the Fraunhofer Institute for Laser production lines will be built in
goal of the IDEA project is to reduce Technology (ILT), the Fraunhofer Insti- the Siemens gas turbine factory in
development and production times in tute for Production Technology (IPT), Berlin and at MBFZ toolcraft GmbH
the powder-based Additive Manufac- and the RWTH Aachen University’s in Georgensgmünd, and will take
turing of complex metal components Machine Tool Lab (WZL) and School of into account the requirements of
by approximately 50%. Digital Additive Production (DAP). small and medium-sized enterprises
Currently the individual work steps IDEA’s priority is to further as well as those of large industry.
along the AM process chain often take industrialise AM for Germany’s The project is part of the Line
place in isolation, from CAD design industrial sector through the use of integration of Additive Manufacturing
to component finishing. IDEA aims to partnerships across the industrial processes (LAF) funding initiative,
bring together fourteen partners from spectrum, with a particular focus on which was created by the German
business and science to drive ongoing linking hardware and software. Digital Ministry of Education and Research
efforts to industrialise and automate twins of products to be manufactured, under the Photonic Research
Additive Manufacturing. the manufacturing process, and the Germany programme. The grant
The partners in the IDEA project entire production line are expected funds amount to just under €14
include the hardware and software to significantly develop AM – which is million. The project is scheduled for
suppliers ALLMATIC, BCT, Jenoptik, still characterised by manual input – a three-year period.
ModuleWorks, and Siemens Digital into a highly-efficient production line. www.siemens.com
Advert 3D Printing_AM Metal.pdf 1 26.09.2019 12:15:50
3D Printing Factory
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Visit us at booth
11.0 D-68 www.hofmann-imm.de
Racing ahead with
additive manufacturing
AM has the power to disrupt, enabling innovative product designs and new
agile business models
Atherton Bikes is taking advantage of these capabilities to break free from the rigid, labour-intensive conventional bike
manufacturing mould. AM gives Atherton Bikes the flexibility to hone their race bike designs, and to make high performance
custom bikes accessible to enthusiasts.
To find out more about the capabilities of our AM systems visit:

www.renishaw.com/amguide
Renishaw plc Brooms Road, Stone Business Park, Stone, Staffordshire, ST15 0SH, United Kingdom
T +44 (0)1785 285000 F +44 (0)1785 285001 E additive@renishaw.com
www.renishaw.com
Materials Solutions becomes first our customers. We knew that in order

to deliver the highest quality parts for
Nadcap-accredited AM provider in UK the aerospace sector we needed to
get the Nadcap accreditation to show
Materials Solutions Ltd – A Siemens and increasing the number of AM we were serious about working in the
Business (MSL), based in Worcester, machines and types of materials it sector. We want to be able to shift the
UK, has become the first UK company processes as it looks towards serial perception of 3D printing from being
to receive Nadcap accreditation production and the industrialisation of a technology associated with proto-
for Additive Manufacturing for the Additive Manufacturing. In addition to typing to a viable option for the serial
aerospace industry. The company has the aerospace industry, MSL supplies production of additively manufactured
been providing additively manufac- to a wide range of sectors including parts for a heavily regulated sector.”
tured parts and components to the oil and gas, power generation, the The National Aerospace and
aerospace industry since its inception tooling and process industries and Defense Contractors Accreditation
in 2006. motorsport. Program (Nadcap) recognises
The business primarily uses Laser Materials processed at its facility companies which have demonstrated
Powder Bed Fusion (L-PBF) for the include nickel-based superalloys, an ongoing commitment to quality
production of high-performance titanium and aluminium, with the by satisfying customer and industry
metal parts, from high-temperature company offering a complete solution specifications. Nadcap accreditation
components for gas turbines and from software through automation, has long been incorporated by the
jet engines to tooling applications, to engineering and manufacturing of aerospace industry into its risk
as well as lightweight structural final applications. mitigation activity, as it validates
components and hydraulic applica- Phil Hatherley, General Manager, compliance to industry standards,
tions. Materials Solutions Ltd, stated, “The best practices and customer require-
The company has grown team are specialists in using Additive ments.
substantially in the past twelve Manufacturing technology to solve www.materialssolutions.co.uk
months, moving into new facilities complex engineering challenges for www.siemens.com
Canadian Research Council partners developing demonstration platforms

targeted at end user-industries and
with PolyControls on Cold Spray AM cluster networks.”
The project is being supported by
The National Research Council of for manufacturers to ensure the Investissement Québec, the Business
Canada (CNRC), headquartered technology is implemented safely and Development Bank of Canada, and
in Ottawa, is partnering with securely. Bank of Montreal, with an initial
PolyControls, a surface engineering “The National Research Council of investment estimated at CAD $4
solutions and equipment integration Canada acknowledges the value and million over the next six years. CNRC
specialist based in Quebec, Canada, importance this collaboration can will also support technology develop-
on the opening of a new research offer the industry and the Canadian ment and provide strategic advice and
facility which will give manufacturers advanced manufacturing ecosystem,” technical services with a professional
and researchers the opportunity to stated François Cordeau, Vice team of over forty experts.
study, adopt and deploy metal Cold President of Transportation and Poly/CSAM is expected to offer a
Spray Additive Manufacturing (CSAM) Manufacturing, National Research combination of unique technologies
technology. Council of Canada. including surface preparation, coating
Expected to open in February “We see great potential in bringing and part manufacturing by CSAM;
2020, the Poly/CSAM facility will be together different stakeholders to local, laser-based thermal treatment;
located at the NRC’s Boucherville enable innovation and to build a in-situ robotic machining and surface
site in Quebec. Specifically, Poly/ network of industrial partners for a finishing; new sensor technologies;
CSAM will focus on scaling-up stronger Canadian supply and value extensive data logging and analytics;
the CSAM process by enabling the chain,” he continued. “Our renowned and machine learning.
adaptation of laboratory-developed technological expertise and Luc Pouliot, Vice-President Opera-
technology to meet factory and mass capabilities in Additive Manufacturing tions, PolyControls, commented,
production requirements. The six research and development will “PolyControls is eager to leverage its
year venture will also offer training support Poly/CSAM and contribute to proven track record in thermal and
cold spray implementation (aerospace
and surface transportation industries)
to showcase its capabilities as a
large-scale manufacturing integrator
offering custom equipment platforms
with the objective of bringing disrup-
tive technologies such as hybrid
robotic manufacturing, data analytics
and machine learning (supported
by Artificial Intelligence) to the shop
floor. We see Poly/CSAM as a way
to strengthen Canada’s industrial
leadership in Cold Spray Additive
Manufacturing and becoming more
agile and competitive on the national
and international scene.”
The new Poly/CSAM facility is expected to open in February 2020 (Courtesy www.nrc-cnrc.gc.ca
CNW Group/National Research Council Canada) www.polycontrols.com
Fraunhofer IWS to hold course on multi-material components. Practical

sessions and guided tours will offer
Hybrid Materials and AM Processes attendees hands-on experience
of multi-material AM, while a
The Fraunhofer Institute for Material information on AM technologies for programme of plenary sessions and
and Beam Technology (IWS) will metal and ceramic components by discussions will offer scientists and
host the 2nd Hybrid Materials and means of hybrid materials. engineers a platform to discuss their
Additive Manufacturing Processes The course will look at latest R&D results in the field.
(HyMaPro) Workshop on December CAE-based virtual design, and Further information and details of
11–12, 2019, at the Fraunhofer Insti- the structural and functional how to register for HyMaPro 2019 are
tute Center in Dresden, Germany. optimisation of AM parts, to AM available via the event website.
The workshop aims to provide devices for the production of www.iws.fraunhofer.de
Industry News
Scan Heads
Encoders, Motors, Drives, &
Mechatronics
Laser Control &

Software
Visit us at
formnext
Customized Solutions for
Frankfurt am Main
Additive Manufacturing Hall 11.1
Applications F48
We deliver mission critical

components and sub-systems that
deliver extreme precision and high
performance, enabling customers
to achieve breakthrough
performance.
Renishaw enables increased fluid Pont, General Manager of Domin

Fluid Power. “After spending years
power capabilities with metal AM on testing different prototypes and
designs we have developed our
Renishaw plc, headquartered in Domin collaborated with Renishaw knowledge in AM that will enable
Wotton-under-Edge, Gloucestershire, to develop a new technology suite for us to produce efficient parts for
UK, has collaborated with Domin the fluid power sector. The company customers. For example, we have
Fluid Power Limited, Bristol, UK, to visited Renishaw’s AM Solutions designed one of our drives that is
help the company maximise produc- Centre in Stone, Staffordshire, UK, to 25% of the original size, 25% more
tivity when designing and manufac- develop their understanding of AM and powerful and produced at a third of
turing direct drive valves. Using metal understand how the technology could the cost.”
Additive Manufacturing techniques, help them produce highly-efficient “At Renishaw we are always
the company can reportedly now drives for customers. looking for opportunities to be
manufacture smaller, more efficient “Metal AM allows you to stretch involved with developing emerging
drives and reduce cycle times from the art of what is possible in the fluid technologies that make positive
five and a half hours to just one. power sector,” explained Marcus changes in the industrial world,”
added Martin McMahon, AM Lead
Technical Consultant at Renishaw.
“We’ve worked with Domin throughout
the whole process, from investigating
material properties, to exploring
the advantages of using the latest
technologies, such as the RenAM
500Q, in production.”
“Additive Manufacturing is a key
technology for Domin,” he continued.
“It gives the company the ability to
build complex parts, free of tooling
and with minimal operations and
assembly. Trying to integrate such
complex functionality into such a
small design would not be possible
using conventional manufacturing
techniques.”
A Domin Fluid direct drive servo valve manufactured using metal Additive www.renishaw.com
Manufacturing (Courtesy Renishaw plc) www.domin.co.uk
Sintavia acquires non-destructive developing field of Additive Manufac-

turing through Sintavia.”
testing company Founded in 1965, QC Labs operates
from three locations in Hollywood,
Sintavia, LLC, Hollywood, Florida, relevant for the Additive Manufac- Florida; Orlando, Florida; and Cincin-
USA, has announced its acquisition of turing industry. Today’s announce- nati, Ohio. The company specialises
QC Laboratories, Inc., a non-destruc- ment is a natural extension of this in radiographic (X-ray & gamma),
tive testing (NDT) services company same process, and we are looking fluorescent penetrant, ultrasonic,
which is also based in Hollywood, forward to deepening the relationship magnetic particle, and eddy current
Florida. The acquisition is expected with QC Labs as we continue to inspections, and holds approvals
to greatly enhance Sintavia’s NDT develop acceptable NDT metrics for for these processes from Honeywell
capabilities for commercial aerospace production AM components.” Aerospace, Lockheed Martin, General
applications, particularly with respect “For more than fifty years, QC Electric, Collins Aerospace, Pratt
to surface finish conformance testing. Labs has been trusted by critical & Whitney, Cessna, Eaton, Aerojet
Doug Hedges, Sintavia’s President industries, including aerospace and Rocketdyne, and Rolls-Royce, among
and Chief Technology Officer, stated, defence, to deliver high-quality NDT others. Post-closing, it is expected
“We have worked with QC Labs for a services,” added John Ahow, QC Labs’ that QC Labs will operate as a stand-
number of years to develop surface General Manager. “It is very exciting alone subsidiary of Sintavia.
finish inspection metrics that are to apply these same services to the www.sintavia.com
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3YOURMIND receives €1.3

million to improve machine
learning for AM
The investment bank of Berlin has awarded AM workflow
software developer 3YOURMIND, Berlin, Germany,
with €1.3 million in Pro FIT funding, co-financed by the
European Regional Development Fund (ERDF). This
funding will reportedly be used to extend machine learning
applications throughout its software suite, designed to
optimise the industrial Additive Manufacturing value
chain.
3YOURMIND’s software helps identify AM-suitable
parts from existing inventories. For companies and
AM services who are already actively using Additive
Manufacturing technology, the software suite is designed
to serve as their digital access point for accurate pricing,
file management, automated order processing and
transparent tracking of the production floor.
In addition to building out machine connectivity,
3YOURMIND will focus on interlinking its software suite
with machine learning to improve depth of optimisation,
lower processing costs and move Additive Manufacturing
towards true automation. It will use the Pro FIT funding to
add artificial neural networks (ANNs) into its software; an
approach for programming challenges which have little or
no explicit, systematic knowledge available.
As a relatively young industry, Additive Manufacturing
is still developing process documentation and best
practice techniques for industrial-scale production. This
is especially true of serial AM. Stephan Kühr, CEO of
3YOURMIND, explained, “Our software makes it simple
and cost effective for companies to enter and scale
Additive Manufacturing. By adding more machine learning
to our software, we will multiply the effectiveness of AM
programme.”
“AM is already a data-driven production method and
we are the leading company to focus on connecting and
optimising workflows using that data” he continued.
“3YOURMIND is developing the software infrastructure
for a level of automation we call agile manufacturing;
the ability to quickly and accurately adapt production to
customer needs and company resources.“
Software is widely thought to be the key enabler for the
industrialisation of AM, accelerating the rate of adoption
by multiplying the effectiveness of individual design
engineers, production engineers and division managers.
The 3YOURMIND team will now analyse part information
and platform usage from opt-in environments and
The FUSION FACTORY is an open source
evaluate non-sensitive data to identify and codify patterns. filament based production system for
Each development test will then be directly cycled complex metal and ceramic parts.
into the software for further validation. The 3YOURMIND
customer list, including AM companies in Europe and the
USA, will be used to ‘train’ the software. xerion.de/fusionfactory
www.3yourmind.com
SLV Halle adds Gefertec’s arc405

metal AM system
SLV Halle GmbH, a research Anhalt to purchase the arc405
institute, located in Halle (Saale), system.
Germany, has invested in the The machine will reportedly be
arc405 system from Gefertec used for additively manufacturing
GmbH, Berlin, Germany. The metal large-volume metal components
Additive Manufacturing system for industries including steel/metal,
uses Gefertec’s 3DMP® process rail/commercial vehicles, machine/
and was installed at SLV Halle’s plant, and pressure equipment
site in June this year. The company construction. SLV Halle reports
states that the machine produces that the results of this work will be
metal components measuring up presented for the first time when
to 0.06 m3 with a maximum mass of it hosts its first AM Symposium on
200 kg. November 12, 2019. Gefertec’s 3DMP process is a wire-
According to SLV Halle, by “We have no doubt that Additive based Additive Manufacturing system
investing in the new machine, it Manufacturing processes can be (Courtesy Gefertec)
aims to strengthen its position implemented more frequently in
in Germany’s growth market for today’s industrial production opera-
generative manufacturing and to tions,” stated Prof Steffen Keitel, forward and make it easier for
promote interest in the further research institute director, SLV metalworking companies to integrate
development of this technology. Halle. “The Gefertec arc405 enables additive manufacturing processes.”
The company states that it received us to drive the strategic expansion www.gefertec.de/en
subsidies from the state of Saxony- of our research infrastructure www.slv-halle.de/en
Specialized in AM 13485:2016 0123

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GE Additive and Bralco Advanced Amit Nanavati, Founder & CEO,

Bralco Advanced Materials, stated,
Materials explore AM magnetic parts “Bralco is honoured to be working
with GE Additive in this very exciting
GE Additive has signed a Memo- Such magnets could be capable of space of digital industry 4.0. This
randum of Understanding (MoU) operating at elevated temperatures, collaboration is a major milestone
with research, product development high frequencies and high torque for us, coming at a time when the
and commercialisation company conditions, characteristics which demand for soft and hard magnets
Bralco Advanced Materials Pte. would make them ideally suited for is growing rapidly due to their use
Ltd., Singapore, for the development demanding applications such as in in every aspect of modern life, be
of metal additively manufactured the traction motors. it healthcare, mobility, personal
magnetic components for applications According to the companies, the communication devices, renewable
in the aerospace, medical, automo- MoU contemplates giving Bralco energy or robotics.”
tive, energy, industrial automation access to GE Additive’s AddWorks “We are very excited to set up our
and robotics industries. engineering consultancy team first R&D Lab and Product Innovation
The MoU aims to progress the and its materials division, AP&C, Centre in Singapore, fully equipped
AM of magnetic components in the potentially enabling Bralco to with a GE Additive machine and a
Asia-Pacific region in particular. It shorten its product development state-of-the-art powder and built
is expected that Bralco’s strength in and commercialisation cycle. The parts testing and characterisation
magnetic materials combined with GE MoU also contemplates the potential lab,” he added. “We hope these steps
Additive’s expertise in powder manu- future appointment of Bralco as a will add to the growing importance of
facturing and AM technology will service provider in the Asia-Pacific Singapore as a global centre for the
enable the companies to accelerate region for the production of parts Additive Manufacturing industry and
the development of soft and hard and components using GE Additive as one of the most attractive locations
magnets and components in complex machines and powders, based to set up a high tech R&D facility.”
shapes, with differentiated magnetic on Bralco’s magnetic materials www.bralcoadvancedmaterials.com
fields and high mechanical strength. compositions. www.ge.com/additive
Rolls-Royce@NTU Corp Lab to include

AM projects in Phase 2
The Rolls-Royce@NTU Corporate systems and improve manufacturing
Laboratory in Singapore, jointly operations in Singapore and other
established by Nanyang Technological global Rolls-Royce sites.
University (NTU), Rolls-Royce and Following the success of Phase 1,
Singapore’s National Research Foun- NTU and Rolls Royce are renewing
dation (NRF) in 2013, has completed their partnership to enter Phase 2
its first five years of research partner- with twenty-nine projects focused
ship and is now moving into its next on developing novel technologies
phase with a joint investment of S$88 that will power the future of aircraft Phase 2 will look at the challenges
million (US$65 million). propulsion. Among these will be involved in Additive Manufacturing
The laboratory was the first projects addressing challenges technology (Courtesy NTU)
corporate laboratory to be supported involved in Additive Manufacturing
under the Singapore public-private technologies, such as finishing and success with more than fifty research
research and development partner- polishing processes for internal AM projects that can create significant
ship between universities and components, and streamlining AM impact in the aerospace industry.”
companies. In Phase 1, it managed workflows. “Building on that success, we are
fifty-three research projects in areas Prof Subra Suresh, NTU President, now moving into the second phase
such as power electronics, data stated, “The Rolls-Royce@NTU Corp with renewed commitment and new
analytics, and repair and manufac- Lab is a fine demonstration of NTU projects that will elevate our collabo-
turing technologies. The research scientists working with the industry ration to the next level,” he continued.
outcomes from these projects are to develop relevant solutions to meet www.ntu.edu.sg
now being used to help design and real-world issues. The first phase of rrntucorplab.ntu.edu.sg
develop future power and propulsion research has achieved remarkable www.nrf.gov.sg
Ad_BeamWatchAM_MetalAM_175x120_E_09_2019_RZ.indd 1 24.09.19 11:37
Fraunhofer IFAM gas turbine According to Fraunhofer IFAM,

the production planning stage was
development showcases potential of particularly important and accordingly
powder bed AM complex to determine the right
technology for each component.
Together with the H+E-Produk- through component optimisation and The accuracy and roughness of the
tentwicklung GmbH in Moritzburg, the possibilities of Electron Beam and surfaces, for example, had to be taken
Saxony, Germany, the Fraunhofer Laser Powder Bed Fusion (EB-PBF into account, as well as the necessity
Institute for Manufacturing Tech- and L-PBF) technologies replace and number of support structures
nology and Advanced Materials (IFAM) the almost 3000 individual parts that and the component size had to be
in Dresden, Germany, has developed make up the original component. considered.
a fully-functional, true-to-scale gas Fraunhofer IFAM was involved in The functionality of the demon-
turbine which demonstrates the the manufacturing of the component strator was a prerequisite for all
current potentials and limitations of as well as the data modification for considerations. For example, the
powder bed-based Additive Manufac- the technology-adapted production. shaft and turbine stages had to be
turing technologies. The housing components, with stator able to rotate freely between the
The demonstrator ‘Siemens stages, were manufactured directly on stator stages and the individual
SGT6-8000 H’, a 1:25 scale model of a site at the Innovation Center Additive components of the demonstrator had
gas turbine for power generation, was Manufacturing ICAM® in Dresden to be connected to each other with
completely manufactured with addi- using EB-PBF of Ti-6Al-4V in a GE minimum effort – by screwing and
tive processes in all areas except for Additive Arcam EBM Q20+ machine. plugging on.
the shaft. The component assembly The turbine stages and the other The components were modified
consists of sixty-eight parts made of housing components were manufac- constructively in order to be able to
aluminium, steel and titanium, which tured at H+E using L-PBF. manufacture the turbine ‘first time
right’. For example, it was made
possible to manufacture the 316L
housing segment by L-PBF without
support structure.
The combination of different mate-
rials commercially available from the
respective plant manufacturers is also
demonstrated in the component. Not
all processed materials correspond to
the target materials for turbines; this
is due to the fact that these materials
cannot yet be processed in such a way
as to be offered commercially.
The scaled model of a gas turbine for power generation, manufactured entirely www.ifam.fraunhofer.de
using EB-PBF and L-PBF (Courtesy Fraunhofer IFAM) www.hedd.de
SIMBA Chain to ensure security for US registration and tracking of

Additive Manufacturing components
Air Force’s Additive Manufacturing during their entire lifecycle.
The SIMBA Chain uses Microsoft
Blockchain sepcialist SIMBA Chain, is the case for all manufacturing Azure for trust and reliability, key
South Bend, Indiana, USA, has been but is especially critical in military factors when providing support on
selected to assist the U.S. Air Force applications, where hostile entities the battlefield. With SIMBA, the
as it seeks to ensure the security of may attempt to obtain or modify Air Force’s BASECAMP project will
its Additive Manufacturing efforts critical data. be able to decentralise Additive
on the battlefield and domestically. To coordinate distributed Manufacturing in the field while
The Air Force uses a complex manufacturing in the field, the maintaining the integrity of data. This
supply chain to equip and repair Blockchain Approach for Supply means that repairs to vehicles cannot
forward-deployed forces. Chain Additive Manufacturing be tampered with by a third party,
According to SIMBA Chain, Parts (BASECAMP) project will as top-secret build plans can be
long value chains are among use the SIMBA Chain platform to transmitted to forward forces without
the biggest security issues in create a prototype demonstrating unwanted surveillance.
manufacturing for Industry 4.0. This a blockchain approach for the www.simbachain.com
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Aurora Labs increases its RMP1 Additive twelve months,” he continued. “The
technical development of our Rapid
Manufacturing speed to 350 kg per day Manufacturing Technology is occurring
in parallel with some exciting progress
Australia’s Aurora Labs reports that it tional manufacturing. David Budge, in our market development activities.”
has substantially increased the speed Managing Director, commented, “This Budge further stated that Aurora
of its Rapid Manufacturing Technology is an outstanding result for Aurora Labs is continuing to make progress
(RMT). Following tests carried out by Labs and one that underlines the with Gränges AB, with whom it signed
the company on its RMP1, the first potential of our metal 3D printing a Memorandum of Understanding on
model in its series of RMT metal capability. Our RMP1 machine has the aluminium Additive Manufacturing
Additive Manufacturing systems, the ability to produce high-quality parts, and the supply of aluminium metal
company stated that it has achieved in a timeframe of hours – as opposed powders in July, to convert the MoU
a build speed of 350 kg per day, an to traditional parts manufacturing into a formal agreement.
improvement of 2000% from its initial that can have lead times of months.” “We have held successful meetings
build rate twelve months ago. “When you consider that we with Gränges in both Stockholm and
The company stated that these recorded print speeds of 15.8 kg Perth to map out the relationship
results show that the RMP1 can per day on the Alpha Printer last and we are now conducting further
manufacture metal parts at a price September, this equates to a greater discussions around research projects
that is cost competitive with tradi- than 2000% speed improvement in and a pre-order for an RMP1 printer,”
he added. The company reported
that it is also seeing interest from a
number of other potential customers,
including a US medical group, two
major global industrial groups, a US
aerospace company, a major global
steel producer and global international
car manufacturers.
“There is no doubt the global
resources, industrial and manu-
facturing sectors are aware of the
potential of Aurora’s 3D metal printing
to reduce costs and free up capital that
is currently locked away in spare parts
inventories, and today’s news will add
to that interest,” Budge noted.
Aurora Labs’ RMP1 can now process 350 kg per day (Courtesy Aurora Labs Ltd) www.auroralabs3d.com
Particle Testing Authority expands its methods, the company can analyse
materials such as textiles (woven
pore analysis capabilities and non-woven), paper, polymers,
metals, ceramics, and porous rocks to
Particle Testing Authority (PTA), a pore sizes of 500 to 0.015 microns. understand how high a throughput can
division of Micromeritics Instrument Parameters such as first bubble be achieved.
Corporation, headquartered in point (corresponding to the largest “We currently measure porosity
Norcross, Georgia, USA, reports that pores present) can be calculated with and pore size using gas adsorption
it has expanded its pore analysis accuracy and repeatability according techniques and mercury porosimetry,
capabilities by implementing to ASTM F-316. so CFP and LLDP allow us to help
Capillary Flow Porometery (CFP) PTA explains that LLDP can more customers address their mate-
and Liquid-Liquid Displacement measure nanopores (1,000 to 2 nm) rial characterisation questions and
Porometry (LLDP). at low pressures by displacing the problems,” stated Greg Thiele, PTA’s
The company states that by using wetting liquid with an immiscible General Manager. “We have performed
CFP, pore properties are calculated liquid at increasing pressure. This various analyses for our customers
by measuring the fluid flow when reportedly eliminates error from in the energy storage industry, and
an inert, pressurised gas is applied collapse or mechanical damage CFP has allowed us to provide a more
to displace an inert and nontoxic caused by high pressure when meas- comprehensive characterisation for
wetting fluid impregnated in the uring materials such as hollow fibres. battery separators.”
porous network of the samples with With these recently implemented www.particletesting.com
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Research project finds AM AF-9628 parts brittle. She went on to additively

manufacture complex designs using
stronger than conventional AM alloys two L-PBF machines at AFIT and
produced appoximately 130 articles.
The Air Force Institute of Technology Hager produced test parts from Currently, the AF-9628 powder
(AFIT), located at Wright-Patterson AF-9628 steel using Laser Powder is only available in small production
Air Force Base, Ohio, USA, reports Bed Fusion (L-PBF). “To determine if quantities and companies can take
that Capt Erin Hager, a graduate of AF-9628 was printable, we character- months to formulate it. As such,
its Aerospace Engineering Program ised the shape and size of the powder while AF-9628 is a less expensive
and an Air Force Research Laboratory and [identified] how it changed with steel, Hager explained that the
(AFRL) employee, recently conducted melting and sieving,” she stated. powder form is not currently
a research project which found that She then examined the steel under cost-effective to acquire since the
additively manufactured AF-9628 a scanning electron microscope demand is low.
parts are approximately 20% stronger (SEM) at AFIT and performed tests Hager stated that she hopes
than parts produced from conven- at the University of Dayton Research that the Air Force will “take this
tional AM alloys. Institute using a size characterising high strength steel and come up
AF-9628 is a steel alloy developed light microscope. After producing with some new applications that we
by AFRL’s Dr Rachel Abrahams, which various parts, she analysed the haven’t even thought of yet.” She
offers high strength and toughness. resulting porosity, strength and recently presented her research
The formula to produce the alloy impact toughness. during an international Powder
reportedly costs less than other high Upon examination, Hager deter- Metallurgy conference and at an
performance steel alloys, including mined that the parts matched the ordnance and ballistics symposium.
Eglin Steel and HP-9-4-20, but is required 10% elongation, indicating www.afit.edu
more expensive than common grades increased strength without becoming https://www.wpafb.af.mil/
used in conventional munitions. It
does not contain tungsten, like Eglin
Steel, or cobalt, part of the formula
for HP-9-4-20.
Sponsored by the Air Force
Research Laboratory Munitions
Directorate at Eglin AFB, Valparaiso,
Florida, USA, Hager’s research found
that AF-9628 is an optimal material
for Additive Manufacturing due to its
high strength. AFIT explained that,
while these findings are comparable to
values reported in a similar U.S. Army
Combat Capabilities Development
Command Army Research Laboratory
study, Hager’s study yielded similar
mechanical properties to convention- Thermal imagery of parts additively manufactured with AF-9628 powder.
ally forged and heat treated AF-9628. (Courtesy photo/Air Force Institute of Technology)
Xiris Automation adds weld microphone The microphone system is

designed specifically for the
system for WAAM process monitoring welding environment and includes
the microphone, cables and a
Xiris Automation Inc., Burlington, According to Xiris, the combina- specialised signal processing
Ontario, Canada, has launched tion of sight and sound monitoring card embedded in the Xiris HMI.
Xiris Audio – a weld microphone while welding will improve operators’ Additional software features enable
system for integration into the Xiris abilities to fine tune and monitor the recording and playback of audio
weld camera system for process the process from a safe distance. in sync with the monitoring video,
monitoring. The Audio is intended for This is especially important for and equalise the audio to enhance
use in arc and sub-arc welding, and critical welding applications where or minimise surrounding noise.
is suitable for use in monitoring Wire the process needs to be monitored www.xiris.com
Arc Additive Manufacturing (WAAM) remotely, such as from a control
processes. room.
AM Solutions expands to add

component manufacturing
AM Solutions S.r.l., Concorezzo, of Additive Manufacturing. This
Italy, the Additive Manufacturing includes the complete engineering
brand of Rösler Oberflächentechnik of components from scratch, the
GmbH, Untermerzbach, Germany, redesign of existing components for
has established a new division Additive Manufacturing, the valida-
focused on the production of AM tion of product designs and topology
components. AM Solutions - 3D optimisation.
Printing Services will compliment The company states that produc-
AM Solutions has established a new
the company’s existing AM Solu- tion of components will take place
division focused on the production
tions - 3D Post Processing division, on state-of-the-art equipment,
of AM components (Courtesy AM
enabling it to cover the entire including an EOS M 290 Laser
Solutions S.r.l)
process chain from engineering and Powder Bed Fusion (L-PBF) system,
design optimisation, to the produc- which allows the manufacture of
tion of components, mechanical component sizes up to 250 x 250 x company reported that it uses a wide
post-processing, surface finishing 325 mm. A number of materials can range of technologies and processes.
and quality control. be processed, including stainless Customers requiring a subsequent
AM Solutions is equipped with steels, aluminium and titanium. machining step will also have access
state-of-the-art software and For post-processing tasks, such to a range of machining equipment,
supporting equipment to ensure as the removal of powder residues including a DMG Mori 5-axis milling
its customers benefit from the and support structures, as well as machine DMU 50.
design flexibilities and possibilities surface smoothing and polishing, the www.solutions-for-am.com
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3D Systems to develop ‘world’s largest, to produce major ground combat

subsystems at scale.”
fastest’ metal AM system for U.S. Army 3D Systems and the National
Center for Manufacturing Sciences
3D Systems, headquartered in Rock the field. The planned build envelope (NCMS) were awarded funding to
Hill, South Carolina, USA, has been is 1000 mm x 1000 mm x 600 mm, create the new system and will
awarded a $15 million contract by the with the ability to build to a minimum partner with ARL and the Advanced
Combat Capabilities Development wall thickness of 100 µm and layer Manufacturing, Materials, and
Command Army Research Laboratory thickness of 30 µm. Processes (AMMP) Program. In
(ARL), to create what has been “The army is increasing readiness addition to bringing a new metal AM
dubbed “the world’s largest, fastest, by strengthening its relationships solution to the army, the company
most precise metal 3D printer.” The and interoperability with business will also evaluate the feasibility of
system is expected to significantly partners, like 3D Systems, who integrating the new technologies and
impact key supply chains associ- advance warfighter requirements at processes into its existing portfolio of
ated with long-range munitions, the best value to the taxpayer,” stated AM technologies.
next-generation combat vehicles, Dr Joseph South, ARL’s Program “Through this project, we’re
helicopters, and air and missile Manager for Science of Additive looking forward to delivering a
defence capabilities. Manufacturing for Next Generation working manufacturing system like
According to the U.S. Army Additive Munitions. “Up until now, powder no other,” commented Chuck Hull,
Manufacturing Implementation bed laser 3D printers have been too co-founder and CTO, 3D Systems.
Plan, the army has been using AM small, too slow, and too imprecise www.3dsystems.com
for two decades to refurbish worn
parts and create custom tools. Once
developed, it will place the new
large-scale systems in its depots and
labs. Subsequently, 3D Systems and
its partners plan to make the new
AM system’s technology available
to leading aerospace and defence
suppliers for development of futuristic
army platforms.
In each of these cases, the
planned system’s large scale and
precision are expected to enable more
efficient design and production of
long-term durable parts with reduced The new metal AM technology is expected to significantly impact key supply
material usage, as well as faster chains associated with long-range munitions, next-generation combat vehicles,
time-to-market for parts going into helicopters, and air and missile defence capabilities (Courtesy U.S. Army)
Boeing HorizonX Ventures investing in through Additive Manufacturing

to more aerospace manufacturing
metal AM company Morf3D partners.”
Following the recent increase in
Metal Additive Manufacturing a number of the world’s largest demand, Morf3D has expanded its
company Morf3D Inc., El Segundo, aerospace OEMs, including Boeing, Additive Manufacturing footprint,
California, USA, which specialises in Honeywell, Collins Aerospace and increased its investment in precision
precision manufacturing and engi- others. machining technology and doubled
neering for aerospace, reports that it “Our latest strategic investment in its workforce with additional
has secured a new round of funding Morf3D extends our commitment to engineering, quality and support
from Boeing HorizonX Ventures our Industry 4.0 efforts – technolo- staff. “It is amazing to see our
following a significant increase in gies that can transform aerospace strategy come to life! Our vision
customer demand. supply chains for future growth to become a world-class leader in
Since the company was estab- and competitiveness,” stated Brian metals Additive Manufacturing for
lished in 2015, Morf3D has helped Schettler, Senior Managing Director, the aerospace industry is truly taking
clients develop, qualify and additively Boeing HorizonX Ventures. “We form,” added Ivan Madera, Morf3D’s
manufacture highly-complex struc- continue to work closely with Morf3D founder and CEO.
tures for flight. It currently serves to help them bring innovation www.morf3d.com
Hydrogen embrittlement of AM nickel- embrittlement,” stated Rincon Troconis.

“This phenomenon causes the prema-
718 in oil & gas industry conditions ture failure of structures as a result
from hydrogen intake in the material.
Researchers from the The University Prof Brendy Rincon Troconis, Hydrogen, once inside the material,
of Texas at San Antonio (UTSA) and UTSA Department of Mechanical interacts with the alloy microstructure,
Southwest Research Institute (SwRI), Engineering, and W Fassett Hickey, degrading its mechanical performance
also based in San Antonio, Texas, of SwRI’s Mechanical Engineering and resulting in brittle fracture without
USA, will collaborate on a research Division, will work to understand the any warning sign.”
project to examine how hydrogen underlying mechanisms governing “By understanding more about
embrittlement conditions develop on the susceptibility of additively hydrogen embrittlement of Additive
a nickel alloy used in the oil & gas manufactured nickel-718 to hydrogen Manufacturing materials, we can
industry, when fabricated through AM. embrittlement under oil and gas provide crucial information, with
According to UTSA and SwRI, industry-related conditions. To more confidence, to optimise the AM
despite many industries quickly do this, they will study hydrogen and post-fabrication processes and
adopting AM there has so far been a embrittlement on a molecular level to prevent brittle fracture of future and
lack of testing of the way hydrogen examine how the location of hydrogen current systems, while advancing the
embrittlement impacts the material atoms affects the integrity of the AM technology, which will all lead to
performance of metal AM parts material under the high pressures better protection of the community,
made from nickel-718, an alloy used and elevated temperatures typical of its assets, and the environment,” she
in critical conditions where high drilling environments. The team will explained.
mechanical properties and corrosion also compare the results obtained The hydrogen study is supported by
resistance are desired. Without from tests performed with additively the Connect Program, a collaborative
enough testing data to understand manufactured nickel-718 with those initiative between UTSA and SwRI, and
the effect of hydrogen embrittlement for wrought nickel-718 under the researchers are expected to have data
on the alloy when processed by AM, same environmental conditions. available by Summer 2020.
the safety of AM-fabricated systems “The operational conditions in the www.utsa.edu
remains unknown. oil & gas industry can lead to hydrogen www.swri.org
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America Makes celebrates seventh institute as we have a great deal of

learnings and achievements from the
anniversary as AM hub last seven years,” he commented.
“We are acutely aware of the needs
America Makes, Youngstown, Ohio, eighty-eight Additive Manufacturing of our industry from commercial and
USA, is commemorating its 7th anni- R&D projects and evolved from a defence sectors.”
versary. Since its founding in 2012, community of sixty-five to more “We are grateful for all of the
the organisation – which is managed than 225 member organisations. support from the DoD, Air Force
and operated by the US’s National America Makes collaborated with Research Laboratory, and other
Center for Defense Manufacturing the American National Standards government stakeholders,” he
and Machining (NCDMM) – has Institute (ANSI) on the creation continued. “As the pilot Institute, we
served as a national accelerator for and publication of the first have proved that the public-private
Additive Manufacturing and the first Standardization Roadmap for AM, collaborative model is effective and
of eight Manufacturing Innovation and has three Satellite Centers important to the ongoing economic
Institutes (MIIs) established and across the USA. success of US manufacturing
programme-managed by the U.S. John Wilczynski, America Makes’ industry. We transitioned from the
Department of Defense (DoD) as Executive Director, stated that he is initial start-up phase and then onto
public-private partnerships. inspired by the promise of the future an incredibly driven project execution
The institute now serves as a not only for the institute but for the phase to where we are today –
hub for advanced manufacturing US manufacturing industry overall. promoting and leading innovation.”
innovation, having executed “This is a really exciting time for the www.americamakes.us
Auburn University employs digital X-ray “It’s a real game-changer

because while we’re building a
CT system for metal AM part inspection component with additive, it’s difficult
to monitor what’s happening,”
The National Center for Additive The NCAME was established in stated Bart Prorok, Professor of
Manufacturing Excellence (NCAME), 2015 and conducts research, trains Materials Engineering and Principal
based at Samuel Ginn College of and educates graduate and under- Investigator on the NIST grant.
Engineering, Auburn University, graduate students, and develops and “With this new system, we can take
Alabama, USA, is set to employ promotes technological innovations two-dimensional X-ray pictures
X-ray CT technology and specialised with the aim of advancing the Additive of a metal structure for real-time
in-house-designed Additive Manu- Manufacturing industry. NASA process monitoring or a series of
facturing systems for the in-process recently awarded Auburn University 2D images in 360° of rotation that
inspection of additively manufactured $5.2 million to develop AM processes are then reconstructed into a 3D
parts. An X-ray CT system was and techniques for improving the representation of the build.”
acquired by the college with the assis- performance of liquid rocket engines. www.eng.auburn.edu
tance of a $1.5 million grant from the
US’s National Institute of Standards
and Technology (NIST).
The new system incorporates a
customised digital radiology vault
from Pinnacle X-Ray Solutions,
Inc., Suwanee, Georgia, USA, which
accommodates Additive Manu-
facturing machines designed and
built by the university’s researchers
to fit within it. This enables the
engineers and partners to conduct
three-dimensional, non-destructive
interrogation of mission-critical metal
parts, as well as providing real-time
monitoring of the AM process. The
system is also able to confirm internal
dimensions of structures and assess An Auburn University researcher examines a 3D rendering of scans produced
the quality of finished parts. by the new X-ray CT system (Courtesy Auburn University)
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kymerainternational.com © 2019 Kymera International

WPI receives $25 million from U.S. Army WPI’s research team plans to
work with several subcontrac-
to develop cold spray AM technique tors, including the University of
California Irvine, the University of
Worcester Polytechnic Institute (WPI), That’s where cold spray comes in.” Massachusetts Lowell, Penn State
Worcester, Massachusetts, USA, has WPI states that its primary University, and Solvus Global. Among
received a three-year, $25 million research focus will include devel- the modifications that are expected to
award from the U.S. Army Combat oping, characterising, and testing new be made to the powders are unique
Capabilities Development Command alloys optimised for use in cold spray. thermal processing treatments,
Army Research Laboratory (CCDC- Cote explained that the characteris- a technique WPI states that it
ARL) to develop cold spray Additive tics of the metal powders used in cold pioneered.
Manufacturing for use in the repair spray are important since the metal Unlike metals used in other metal
and production of metal parts. is not melted before being sprayed manufacturing processing, including
WPI’s cold spray Additive Manu- onto a part that needs repair, nor heat casting and forging, the alloys used in
facturing process uses a pressurised treated after application. cold spray do not have to be capable
gas to accelerate metal powders to Cote added, “With most manu- of being heat treated, which gives
near supersonic speeds. The force facturing methods, metal alloys are the WPI researchers access to a
of impact causes the powders to alerted by first being melted, and then wide range of potential materials.
adhere to the metal build surface. often heat treated to strengthen or However, the properties of cold spray
The institute explained that the otherwise improve their properties. powders can be fine-tuned with the
process can be adapted to work with a With cold spray, what you end up with careful application of heat.
portable handheld applicator, making in the repair is exactly what you start Cote further added, “This
it suitable for use in the military field. with, so the characteristics of the expertise is part of the reason the
“The army is interested in cold powders are quite important.” ARL continues to support WPI. We
spray 3D printing as a repair tech- As part of the research, the have discovered that the properties
nique,” stated Danielle Cote, assistant institute will reportedly use a variety of metal powders can be significantly
professor of materials science and of equipment, including instruments enhanced with thermal processing,
engineering and director of WPI’s acquired as part of the new ARL and that is what we are looking to do
Center for Materials Processing Data, award. These include tools to study with this new award.”
and the principal investigator for the the chemical and structural proper- As part of the research
ARL project. “It’s cheaper to repair a ties of the powders at the scale of programme, a team of co-principal
part than to replace it, and you get the nanometers, such as a SEM/EDS investigators from multiple disci-
equipment back in service faster.” (Scanning Electron Microscope and plines at WPI will explore some new
“The army’s primary interest is Energy Dispersive Spectroscopy) unit, applications, including the use of
unit readiness,” she continued. “If a synchronous laser diffraction and cold spray to apply copper coatings
you’re on a mission and need to move dynamic image particle analyser to to give equipment antibacterial
quickly to a safer place, and a critical determine powder morphologies, and properties. Researchers in WPI’s
part on your vehicle breaks, you’re nanoindenters to measure nano- robotics engineering programme will
stuck unless you can repair it quickly. scaled mechanical properties. explore the use of multi-axis robots
to automate the cold spray process.
Cote continued, “The army is
especially interested in portable cold
spray systems, but the technology
can also be used on a larger scale
in industry, for example and it will
be exciting to see how robots can
help expand the use of this and other
Additive Manufacturing processes.”
“I think there is much potential for
this technique. With the work we will
be doing with powder development,
in robotics, and in a number of other
areas, I think we are going to go
a long way with cold spray. There
really are endless possibilities,” she
concluded.
Cold spray Additive Manufacturing can be used to perform surface repairs on www.wpi.edu
damaged metal structures (Courtesy Worcester Polytechnic Institute) www.arl.army.mil
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GE Additive optimises design for

brewing equipment by AM
The team at GE Additive’s Customer According to Dr Matthew
Experience Center (CEC) in Munich, Beaumont, GE Additive’s CEC Munich
Germany, has worked with brewing site leader, “the design team was
equipment manufacturer Kaspar quickly able to come up with a design
Schulz GmbH, Bamberg, Germany, to efficiently loosen the spent grains
in the development of a racking and inject water, throughout the bed,
blade used in a lauter tun during during rotation. The design of a thin The racking blade incorporates
the production of beer. blade that has internal channels to internal channels to distribute water
On redesigning the racking distribute water evenly is only achiev- evenly (Courtesy GE Additive)
blade, the goal of Kaspar Schulz able using Additive Manufacturing.”
was to improve the filtration effect Dr Benedikt Roidl, advanced were able to do simulation analysis,
of the spent grain bed in the vessel lead engineer at GE Additive, added complete the design and perform
in order to rinse it more thoroughly, “Together with Mr Binkert and his basic functional tests before now.”
saving time and increasing team, our specialists CEC in Munich “What still lies ahead of us,
efficiency. “We were very pleased evaluated how to improve the though, is the final use verification
that GE Additive approached us,” lautering process and we came up in the complete brewing process.
stated Jörg Binkert, head of R&D with the idea of dynamically loosening We want to verify the benefit via
at Kaspar Schulz. “We were already the spent grain using an induced chemical analysis of an actual batch
familiar with 3D modelling and swirling flow field.” of wort – and of course a taste test by
making designs with CAD, but Addi- Beamont added that, “We set the the project team!”
tive Manufacturing was something goal of achieving a first design in time www.ge.com/additive
new for us. for this year’s Oktoberfest, and we www.kaspar-schulz.de
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OF_ad_MAM175x120_RZ_27.08.2019.indd 2 27.09.2019 07:45:31
Senvol President elected chairman

of SME’s Additive Manufacturing
Community Advisors
Zach Simkin, president of Senvol, “AM continues to be a major
New York, USA, has been elected to strategic initiative for SME and a vital
serve as Chairman of the Society of emerging sector for manufacturing
Manufacturing Engineers (SME)’s as a whole,” stated, Suzy Marzano,
Additive Manufacturing Community. Product Development Manager at
SME’s AM Technical Community Advi- SME who oversees SME’s Technical
sors serves as the primary resource Communities. “We’re thrilled at
for guidance to SME and its members Zach’s selection as Chairman for the
on Additive Manufacturing technolo- upcoming year, we appreciate his Zach Simkin with outgoing chair,
gies, including materials, processes, vision and leadership, and we look Jennifer Fielding (Courtesy Senvol)
industrial base and workforce. forward to working with him and the
The role of an AM Community rest of the AM Community Advisors
Advisor is to “provide timely and to help further SME’s leadership Research Laboratory, commented,
expert guidance” to SME on AM position in the industry.” “I’ve had the pleasure of working
activities, initiatives and content to Simkin is currently in the third year with Zach for several years. He is
best serve the Additive Manufacturing of a three-year term as an Advisor, extremely committed to helping the
community. The AM Advisors also and previously served as Vice Chair AM industry advance and is a true
serve as ‘faces of the industry’ for before being elected Chairman. thought leader in the industry. Under
SME. Community Advisors are report- Jennifer Fielding, the outgoing Chair his stewardship, SME’s AM Advisory
edly chosen based on a combination of SME’s Additive Manufacturing Committee will continue to pave the
of active industry contributions, Community Advisors and Section way for the industry’s advancement.”
reputation and personal commitment Chief, Composite Performance and www.senvol.com
to expand the use of AM. Applications Section at Air Force www.sme.org
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Florida doctor implants US-first metal ironworking accident in 2017, drasti-

cally hindering his hand’s mobility.
additively manufactured finger bone Smith was initially presented
replacement with the choice to live with the

injury – which reportedly left him with
no function and little feeling in the
Dr Daniel Penello, of Alexander manufactured finger bone implant, affected finger – or to opt for ampu-
Orthopaedic Associates, St. reports Fox 13 News. tation of the digit. However, following
Petersburg, Florida, USA, has The implant was designed for further research and with the
successfully implanted what is said patient Robert Smith, whose middle assistance of Additive Orthopaedics,
to be the US’s first metal additively distal phalanx was shattered in an Little Silver, New Jersey, USA, Dr
Penello was instead able to develop a
metal additively manufactured finger
bone implant, custom-designed to fit
Smith’s measurements.
According to local news station
WINK, the implant was produced
on a GE Additive Arcam Q20plus
system by FIT America. Following the
surgery, Smith is reported to have
regained full mobility in the affected
finger and has been able to return to
work.
“I’m fascinated because
technology is really changing the
way health care is being delivered,”
stated Dr Penello. ”To be able to
have full use and function of the
finger, just like it never happened, is
absolutely incredible.”
The shattered distal phalanx of Smith’s middle finger (left) was replaced with www.alexanderorthopaedics.com
a metal AM implant (centre and right) www.additiveorthopaedics.com
Asiamold 2020 to take place in November 19–22, at Messe Frankfurt,

Frankfurt, Germany. Intermold Japan
Guangzhou, China 2019 be held from April 17–20, in
Tokyo, Japan, and June 19–22 in
Asiamold 2020, organised by field of Additive Manufacturing, the Nagoya, Japan. Rosmould 2019 will
Guangzhou Guangya Messe Frankfurt 3D Printing Asia zone was said to run from June 18-20 in Moscow,
Co Ltd., will be held at the China have been a key highlight of the show, Russia. The first edition of Formnext
Import and Export Fair Complex in showcasing a series of cutting-edge + PM South China will be held from
Guangzhou, China, from February AM technologies and solutions by September 9–11, 2020, in Shenzhen,
26–28, 2020. The event will be held prominent brands in the region. China.
concurrently with SPS – Industrial Some of the exhibitors reported to Zhang Mingfu, General Manager
Automation Fair Guangzhou (SIAF), have confirmed their attendance at of Hostar Hotrunner Technic Co Ltd,
and will bring together leading Asiamold 2020 include: Beijing Tenyoun stated, “Asiamold is always a good
brands in the tool, die and moulding 3D Technology, Dongguan Chuangyi platform for us to gain company
industries and cover a diverse range Metal Product, Dongguan Gunri exposure and to showcase our latest
of metalworking technologies. Precision Mold, Dongguan U-Light innovations in hot runner systems.
The 2019 edition of Asiamold, Mould, Guangzhou Songxing Eletric, We are able to meet a number of
held together with SIAF, attracted Hostar Hotrunner Technic and JK Mold. overseas visitors here, which is very
over 98,000 visitors, and welcomed The organisers state that the event crucial and beneficial for us to enter
more than 988 exhibitors from twenty programme is still to be be announced. the international market, providing
countries. A number of ‘thematic Asiamold forms part of a series of us the opportunities to export our
zones’ once again contributed to the international events including Form- products abroad.”
2019 show’s success. In line with next, Intermold Japan and Rosmould. www.asiamold-china.
China’s rapid development in the Formnext 2019 will be held from cn.messefrankfurt.com
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Paper submissions now open for conference focused solely on metal

Additive Manufacturing, and in 2020
WorldPM2020 and AMPM2020 will feature an extra day of technical
sessions. Topics will include process
In 2020, the World Congress on Powder In addition to the conference, there modelling, design of components,
Metallurgy & Particulate Materials will be a major exhibition featuring powder production, post-build opera-
(WorldPM2020) is heading to Montréal, a wide range of international exhibi- tions, materials and testing.
Canada, from June 27–July 1, 2020. tors and providing an opportunity The Tungsten2020 conference aims
Taking place every two years, the for networking with material and to address recent developments in
series rotates between North America, equipment suppliers, part producers the refractory and hardmetals field
Europe and Asia, bringing together the and end-users. and will encompass refractory and
global Powder Metallurgy community hardmetal processing, microstructure,
for the largest event in the industry. Co-located events to bring added properties, and applications. Papers
The Metal Powder Industries value to the World Congress are requested on topics including
Federation (MPIF), organiser of the Co-located with WorldPM2020 will powder production, processing,
2020 congress, has issued a call for be the 2020 Additive Manufacturing mechanical behaviour and modelling.
papers and posters for the technical with Powder Metallurgy conference
programme. The conference will (AMPM2020) and the 10th Interna- Call for papers
cover the full range of Powder tional Conference on Tungsten, Those authors wishing to present
Metallurgy topics, ranging from metal Refractory & Hardmaterials at the WorldPM2020 congress,
powder production and technology, (Tungsten2020), both taking place AMPM2020 or Tungsten2020 should
powder compaction, sintering and over the same days and allowing even submit their abstracts online no later
post-processing to Metal Injection greater interaction across the metal than November 15, 2019. Full submis-
Moulding, cemented carbides, porous powder-based industries. sion guidelines are available via the
materials, Additive Manufacturing According to the MPIF, the AMPM organiser’s website.
and the design and simulation of PM conference has grown significantly www.ampm2020.org
parts. since its debut in 2014 as the only www.worldpm2020.org
Cubed Technology to Certify Metals.
Keselowski Advanced Manufacturing Elementum 3D’s IP technology,

reactive Additive Manufacturing (RAM),
and Elementum 3D partner on metal AM is said to prohibit cracking that usually
happens during solidification, while
Keselowski Advanced Manufacturing Elementum 3D’s 6061 powder, KAM achieving or exceeding the same
(KAM), Statesville, North Carolina, will reportedly be able to additively properties of the traditional alloys.
USA, and Elementum 3D, Erie, manufacture parts at an average of Additionally, Elementum 3D’s ability to
Colorado, USA, will collaborate to 65% faster. The companies report develop customised materials to match
create new opportunities for entry that they will also work together on wrought properties, such as the 6061,
into the Additive Manufacturing different development projects in provide a solution to materials that are
industry. Under the collaboration, Additive Manufacturing, including not printable in their current form.
Elementum 3D will supply KAM with the testing of new materials. “I love what they’re doing at
advanced materials for AM such as Jacob Nuechterlein, Elementum Elementum 3D,” commented Brad
A6061- RAM2 powder, said to be the 3D’s president and founder, stated, Keselowski, founder and CEO of
only Additive Manufacturing material “Elementum 3D’s commitment KAM. “Their materials enable KAM
comparable to wrought 6061-T6 to the development of advanced to engineer and manufacture metal
properties. materials aligns well with KAM’s 3D printed parts that are faster and
According to the companies, innovative growth plan based around higher in quality than anything that
aluminium 6061 is a commonly-used hybrid manufacturing. We are proud is currently out in the marketplace. I
aerospace and automotive aluminium to partner with their team and think we’re going to continue to do a lot
alloy which was previously impossible evolve our technologies together. of innovative work together that’ll lead
to additively manufacture. KAM There’s increasing demand within to positive developments within the
states that it will be the first and only our customer base for aluminiums additive community. It’s a really exciting
supplier in North America to use like the 6061. It’s taking off and this time for both companies.”
6061 in an SLM 280 system. With material is at the forefront of the www.kamsolutions.com
the combination of the SLM 280 plus trend.” www.elementum3d.com
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• Aluminum based premix powders
Tel: +1 610-826-7020 (x215)

Email: sales@usmetalpowders.com
www.usmetalpowders.com
USMP
A M PA L | P O U D R E S H E R M I L L O N
Aero engine cylinder design optimised

by Cobra Aero and Renishaw
Cobra Aero, an engine manufacturing volume applications, speed up the
company based in Michigan, USA, has manufacturing process and produce
invested in a Renishaw AM 400 metal designs that would not be possible
Additive Manufacturing system after using conventional subtractive
working with Renishaw to improve machining.”
the design of aircraft and motorcycle Hilbert added, “We decided to
engines. redesign the cylinder because of
Cobra Aero worked with Renishaw its importance in an engine. Design
engineers to gain expertise in Additive changes to this part of the engine
Manufacturing, visiting Renishaw’s must happen rapidly, and it is also a
USA Additive Manufacturing Solutions high value part, which is why we have
Center. The companies collaborated chosen to additively manufacture
to optimise an engine cylinder this component. Improving the
used in an unmanned aerial vehicle performance of the cylinder will also The optimised engine included a
(UAV), where the use of AM allowed improve the overall performance of lattice structure to increase airflow
the design to incorporate a lattice the engine.” (Courtesy Renishaw)
structure to increase airflow, as well Stephen Anderson, AM Business
as being strong and lightweight. Development Manager, Renishaw –
“Staying at the cutting edge USA, stated, “By using metal Additive produce a single part with complex
of manufacturing is important to Manufacturing, Cobra Aero was able lattice structures that performs
Cobra Aero,” explained Sean Hilbert, to design a part that was unique better than conventional component
Cobra Aero President. “Investing in to the application. By using our manufacturing techniques.”
AM allows us to develop tools and Laser Powder Bed Fusion (L-PBF) www.renishaw.com
new products for high-value, small- technology, Cobra Aero was able to www.cobra-aero.com

Conference Industrial Perspectives
in Additive Technologies
November 25-27, 2019

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| contents | news | events | advertisers | website | e-newsletter | Sintavia’s new AM facility
Sintavia: New facility signals the

move towards volume metal
Additive Manufacturing for
aerospace and defence
In May 2019, US-based Sintavia, LLC opened a state-of-the-art facility in
Hollywood, Florida, dedicated to the volume production of metal additively
manufactured components for the aerospace and defence sector, marking a
significant expansion of the company’s production capacity. Debbie Sniderman
visited the new facility on behalf of Metal Additive Manufacturing magazine and
reports on the company’s ambitious plans and its management’s views on the
ongoing evolution of the industry.
Earlier this year, Sintavia, LLC, $100 million and now serves as the pre-processes, builds, post-processes,
a leading independent metal AM company’s headquarters, originally and analyses all aspects of Additive
service provider for the global located in the nearby town of Davie. Manufacturing in-house, from start
aerospace and defence industries, Sintavia’s mission with this new to finish. With this business model,
formally opened its new 5,100 m2 facility has been to be amongst the Sintavia believes that it is well posi-
Additive Manufacturing facility first independent manufacturers to tioned to supply serially manufactured
in Hollywood, Florida, USA. With offer a vertically integrated, end-to- aerospace and defence components
high-speed Additive Manufacturing end metal Additive Manufacturing with guaranteed quality and repeat-
systems co-located alongside production process. It designs, ability as part of an OEM supply chain.
a high-capacity precision post-
processing operation and a full
complement of quality control and
testing services, this new facility is
able to deliver along the entire AM
process chain, from component
development and parameter
optimisation to serial production and
inspection.
When fully commissioned, it
is expected to be one of the most
advanced Additive Manufacturing
plants in the world, capable of
producing thousands of precision
metal components per month for
the aerospace and defence OEMs
worldwide who are recognising
the economic, technical and
strategic benefits of the technology.
The facility is anticipated to
generate revenue in excess of Fig. 1 Sintavia’s new AM facility in Holywood, Florida, USA
Sintavia’s new AM facility | contents | news | events | advertisers | website | e-newsletter |
Sintavia provides are acceptable to

customers. There are, of course, a
number of cases where customers
want to test parts in their own
approved facilities,” he added. “We
are continually improving and, as
we grow, we add quality systems
and special process approvals. The
eventual goal is to have all customer
quality systems in place here, so
customers don’t have to send parts
to other testing laboratories all
over the country. Our path is to have
Nadcap credentials for all of our
processes, not just AM, be it special
metallurgical processes such as heat
treating, Hot Isostatic Pressing, or
X-ray CT scanning, etc. In modern
advanced manufacturing, complete
vertical integration is the path people
are looking for.”
The company’s metallurgical
laboratory has been a key part of its
operations from the beginning. Over
time, it has complemented these
capabilities with X-ray CT scanning
for dimensional characterisation and
Fig. 2 The entrance area to Sintavia’s new facility, which is designed to house internal inspection. It also has tensile,
sixty large- and medium-sized metal AM machines fatigue, creep and impact testing
capabilities that support its ability to
confirm heat and high-vacuum heat
treatment with mechanical testing
Vertical integration built and certifications are a large part of according to quality standards and
the process and have been our goal specifications. This in-house capa-
around quality bility is said to be critical for material
from the beginning. While quality
In explaining what it means to be systems are baseline and standards and parameter development.
vertically integrated in the aerospace such as ISO are rigorous, customer
and defence sector, Doug Hedges, quality systems are even more
Managing raw materials:
President of Sintavia, told Metal AM, rigorous. It has been our culture to
Powder pre-processing and
material development
“Accreditations and certifications are a Sintavia analyses raw powder

material when it arrives to ensure
large part of the process and have been that suppliers have done their
our goal from the beginning. While quality due diligence. It also tests powder
throughout a build, providing reports
systems are baseline and standards such to the customer. Sintavia’s accredited
as ISO are rigorous, customer quality powder laboratory uses diffraction
analysers, SEM, ICP-OES, gas
systems are even more rigorous.” analysis tools, flowmeter testing and
true density testing equipment.
As well as processing established
mainstream AM alloys, Sintavia also
“For aerospace and defence, quality abide by them and continually improve works closely with its customers to
is number one. We have to be good at in a quality fashion,” he stated. develop both new alloys and powder
these services and can do every core “In many cases, the mechanical strategies for AM adoption. The
process involved in AM. Accreditations testing and laboratory services that company states that it was the first
Fig. 3 EOS M400 systems installed at Sintavia for the production of components for the aerospace and defence sector
AM company to develop a proprietary to reduce the risk of inhalation and to the series production of quality-
process for the Additive Manufac- combat the possibility of contamina- critical metal AM parts. In addition to
turing of F357 aluminium powder. Its tion. Whilst during the build process powder source and qualification data,
customised parameters, processes most of the powder goes into the ERP and PLM systems track every
and quality control procedures make build chamber, some goes into the part, bin and lot of powder as it moves
it possible for Sintavia to serially overflow and is recovered. The powder through the manufacturing process.
manufacture parts and audit quality rooms’ industrial sieving processes, Data from serial and lot numbers
parts for critical industries. with vibrating screens, support contain all machine and telemetry
Sintavia has three powder rooms powder recovery and reprocessing. information, oxygen levels throughout
dedicated by powder type, for storage Robust tracking processes for the build process and tensile
and preparation of powder before use powders ensure that before powders specimen test results. These can
and to process recovered powder after are used or reused, they are sampled be compiled quickly into a customer
use. Containers are filled with inert in the laboratory at Davie to check report.
argon gas to displace oxygen and that element levels are within
prevent contamination and oxidisa- specification. Powders are reused
tion; this is particularly important for a number of times, depending on AM production, post-
reactive powders such as titanium customer requirements, until they processing and inspection
and aluminium. fall out of specification. For clients
Sintavia’s powder recovery areas which require virgin powders for their Having a variety of AM production
and powder removal stations have components, Sintavia keeps certain systems installed, including some of
negative air pressure, so any acci- amounts of these materials in store. the most widely used in the industry,
dentally released fine particles pass Combining the physical tracking gives Sintavia the flexibility to optimise
through filters instead of escaping of materials through the facility with production for its customers’ needs.
into the wider area. Full face shields the requirement for recording high Component manufacturing currently
and respirators are worn while volumes of process data can be a takes place using eighteen AM
working in these finishing rooms significant challenge when moving machines from five different OEMs.
These comprise eleven EOS systems

(two M400-1s, four M400-4s, and five
M290s), three SLM Solutions 280s (two
twin-laser, one single), one Concept
Laser M2 dual-laser system and a
Trumpf TruPrint3000. Two Arcam
systems, an Q20+ EBM, and A2X EBM
are also installed.
The new facility’s lower production
floor is divided into two equally sized
halls, one with space for fifteen EOS
M400s or the equivalent dedicated
to nickel superalloys, Inconel 625
and 718, and heavier alloys, and
one designed to handle large-scale
builds using primarily titanium and
aluminium. The upper production floor
has space for twenty-five M290s or the
Fig. 4 High speed machining centres
equivalent for smaller builds.
All core post-processing operations
are performed in a large finishing and
machining area. A new, GM vacuum
furnace that can fit six large 40 cm
x 40 cm build plates at once, with a
weight of more than 1000 kg each,
is located in this area, as well as a
Quintus Hot Isostatic Press, wire
EDMs, CNC mills and lathes, band
saws and wet and dry blasters.
Sintavia is one of few suppliers
in the marketplace that has HIP
in-house, an integral part of the
manufacturing process for critical
parts produced by metal AM. This
minimises the need to send parts
to external contractors for further
processing, reducing cost and lead
time and allowing full control to be
Fig. 5 Wire EDM machines kept in-house.
All final production quality
and conformance inspections are
performed in a new quality controlled
inspection lab. This contains blue light
scanning technology, which scans
finished production parts on a rotating
turntable, creating a 3D rendering
of the part to make sure it conforms
to requirements. SPC and CMM
programmable fixtures ensure quality
processes are the same.
First article inspections on
qualification builds take place at
Sintavia’s Davie location using a CT
scanner for dimensional metrology.
“There are many radiography speci-
fications for size inclusions, allowed
voids and the distance between
Fig. 6 A lathe and band saw for the post-processing of AM parts voids,” explained Hedges. “Our CT
Fig. 7 A post-build processing area at Sintavia
scanner has high enough resolution as commercial flight hardware. The and make internal engineering happy –
that it allows us to go beyond most piece that Sintavia built received and that we can do the job better than
customers’ radiography specifications approval and is now proven to go into the traditional supply chain in the form
to verify if there were problems. Every one of the largest narrow body fleets. of lower costs, shorter manufacturing
fifth part is scanned until qualification Every other part on the production times, and dramatic design improve-
is complete, then every twenty-five or chain was manufactured by the OEM ments.”
a statistical sampling after building a itself, making this its first part made “Getting approval from our largest
trust relationship. It’s hard to do; we by an independent Additive Manufac- customer is a big deal,” he continued.
are disrupting the whole industry. This turing firm. “It signals that it’s the first time
is the next industrial revolution.”
Sintavia is AS9100 and ANAB certi-
fied, OASIS and ITAR registered, ISO
9001 and ISO/IEC 17025 accredited,
“We wanted to prove to OEMs and
and A2LA approved. Its laboratories customers making precision cast parts
are also both accredited, as required
by customers. The company has that a simple non-rotating metal part
Nadcap certification for Additive
Manufacturing, and further plans
could conform to specs and make
to obtain this for heat treatment, internal engineering happy – and that we
post-processing later this year.
can do the job better than the traditional
Expanding the range of
supply chain...”
applications for AM in
aerospace and defence Brian Neff, Sintavia’s CEO, stated, the technology is acceptable for
“We wanted to prove to OEMs and commercial parts. This part, a simple
In April 2019, a major aerospace customers making precision cast filter cap, is only one part. The road
OEM accepted delivery of its first parts that a simple non-rotating stretches ahead over hundreds of
Sintavia metal AM part to be installed metal part could conform to specs thousands of parts over the next twenty
Fig. 8 One of five EOS M290 systems installed at Sintavia’s new facility
years. We see the path forward to in include valve bodies, ducts, Sintavia also manufactures
meet demand. We’ve done it for chassis, and heat exchangers. flow control valves for commercial
the first time and expect it to grow AM has long been recognised aerospace and other critical
rapidly. There were no deviations; as a natural production process industries, noting that the production
we met the drawings. There were no for heat exchangers because of flow control valve assemblies is
manufacturing review boards; the of its ability to create internal greatly simplified when using AM,
part was completely accepted. Now passageways in geometries with shorter lead times and fewer
someone has proven a third-party that cannot be manufactured part assemblies.
Heading towards
“The casting and forging industry that displacement
supplies aerospace products is huge and “Sintavia is trying to become the
AM will replace precision casting over time largest independent metal AM
because it is a competitive alternative. The supplier for the aerospace and

defence markets,” Neff stated. “OEMs
technology itself is cheaper, faster, more typically rely on supply chains to
manufacture a lot of their equipment
efficient, and much less polluting.” for many reasons. They design,
test, sell and assemble, but do not
fabricate. The casting and forging
industry that supplies aerospace
can manufacture using AM so the by traditional methods. Sintavia products is huge and AM will replace
promise is there. It’s no longer hype.” manufactures heat exchangers precision casting over time because
Other aerospace and defence for several industries and can it is a competitive alternative.
applications that the company manufacture wall thicknesses of The technology itself is cheaper,
has developed specific expertise 200 µm or less. faster, more efficient, and much
less polluting. CEOs and aerospace

leadership want to adopt a new supply
chain that offers a technical and
strategic advantage as well as having
an alternative to the traditional chain.
Sintavia has made good strides in
filling this gap and is building itself as
a leader for independent aerospace
and defence projects.”
He sees the metal AM industry
growing as it displaces traditional
casting houses – which is a $100+
billion industry globally – every year.
“Whilst the smaller AM houses are
to some extent competitors, the real
challenge is to displace companies
such as Precision Castparts Corp
(PCC), Consolidated Precision Prod-
ucts (CPP) and Arconic,” he explained.
“Sintavia is committed to establishing
an alternative and parallel supply
chain for precision cast parts within
the aerospace industry.”
Demand, Neff believes, will
come from middle management
such as Program Managers for a
specific engine or aircraft who trust
the technology enough to take the
risk and put it on their engines. “An
under-capitalised family business
with a machine or two cannot take
this on - but Sintavia can. The Chief
Engineers on an A350 or 787 are the
decision makers we need to convince
to adopt the technology.”
Fig. 9 An industrial scale GM vacuum furnace for the heat treatment of AM

The challenges of standards
builds
and AM
“We are bridging two worlds – the

world of AM, science, technology and at the company, in addition to its of government bodies to move the
manufacturing in general, and the core competency in metal AM. “It’s a industry forward. Now that AMS has
unique world of aerospace produc- challenge to learn them all quickly, standards based around AM, others
tion, which is tough,” Neff stated. because the industry is moving will come out. It needs to be done
“Quality requirements are the most so fast. The technology is moving quicker to keep up with how fast the
stringent in the industrial world. A faster than the standards. We know technology is moving. Documentation
failure seven miles up is catastrophic. a process is good but the standards and standardisation are slightly behind.
The challenge is not only to master for making aerospace parts are Instead of waiting for government
the technology to manufacture to controlled by the SAE’s Aerospace bodies to release, we write the
a precise and high-quality degree Materials Specifications [AMS], and specifications internally or work with
but conform it to a stringent quality there’s no infrastructure for other customers to write specifications to
management system, meeting what manufacturing processes,” Hedges control the processes so they are fixed
the customers want.” added. and repeatable. It is also challenging
Peripheral services offer a “Many standards are guarded that many of these company
challenge too; testing and post- or controlled as IP at different specifications aren’t transparent
processing means there are five or companies. We are just now throughout the industry. But the
six divisions with different skill-sets starting to see documents flow out industry could adopt all of them.”
Fig. 10 Arcam Q20+ and A2X EBM machines at Sintavia
A maturing supply chain themselves for commercial air Sintavia is on that glide slope
travel. At a high level, it’s always curve now, moving into the realm
Neff believes that Sintavia’s success been something our customers have of producing tens of thousands of
in gaining acceptance for its first wanted to do. We received our first parts per year. Once we start with
metal AM part in a commercial production contract in the last half one, more will come,” he stated.
airliner is evidence that the supply of 2018 and have proven it now in the Hedges agreed: “A few years ago
chain has been developed to the first half of 2019.” the supply chain was small. It’s still
small today, but is getting bigger
as more established companies,
like Sintavia, make aerospace parts
“In the next two-to-ten years we for real flying engines. The supply
will start to see suppliers becoming chain is further along, moving ahead
and evolving to gain strength and
more refined and narrowing their experience.”
“I don’t think there will ever be a
skill sets. Instead of doing it all, they single supply chain. We are seeing
will focus to be really good at certain that in this industry, one supplier
can’t do it all. The supply chain itself
components.” is specialised, with three or four
companies that may specialise in
making a certain component. In the
scale and quality required to move “With any new technology in next two-to-ten years we will start
the process from the fringes to the critical industries, at first, the to see suppliers becoming more
mainstream. “We’re now at the point adoption rate is always slower than refined and narrowing their skill
where our customers are accepting everyone wants. But it then reaches sets. Instead of doing it all, they will
parts they didn’t manufacture the point where it rapidly accelerates. focus to be really good at certain
components. For example, for us

to produce high-pressure ducting,
competing suppliers may need to
specialise in steel and aluminium.
There’s a lot of room for growth in
these supply chain-type companies,”
he concluded.
Blueprint for growth
In the next three-to-five years,

Sintavia plans to focus on ensuring
that its new facility is able to reach
capacity by employing 130 highly
skilled workers and generating more
than $100 million of annual revenues
on the production of parts in the tens
of thousands - a tremendous growth
track. At the close of 2018, Sintavia
had thirteen metal AM machines in
operation. By the end of 2019 it will
have twenty-two. Its new facility,
with its capacity for sixty large and
medium machines, is the prototype
for future growth.
Looking ahead, Sintavia told Fig. 11 A view of the heat treatment area at Sintavia
Metal AM that it will replicate its
vertically-aligned business model
in locations across the US and
Canada near its OEM customers.
It is currently in the process of Contact Author
building a second production facility
in Houston, Texas, USA, which Carolyn Allan Debbie Sniderman
will primarily service the oil and Director of Marketing and Strategic CEO of VI Ventures LLC, an engi-
gas industry. Future locations are Sales neering consulting company
planned for Seattle, Washington, Sintavia, LLC info@vivllc.com
USA, and Phoenix, Arizona, USA, and CAllan@sintavia.com
later in Japan and Europe. www.sintavia.com
For the world of

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| contents | news | events | advertisers | website | e-newsletter | All you need to know about sintering
Thinking about metal Binder

Jetting or FFF? Here is (almost)
everything you need to know
about sintering
With the arrival of high-volume metal Binder Jet systems and a growing interest in
metal Fused Filament Fabrication, the AM industry is set for a new phase of growth.
The ability to use this new generation of systems for the production of ‘green’
parts is, however, only half of the story. The sintering of these parts to create large
quantities of finished product to a consistent quality requires both an investment in
furnaces that can cost in excess of $1 million each, and a thorough understanding of
sintering. In this article, Prof Randall German, the leading authority on the science
of sintering, outlines the process and its core challenges.
Sintering is a heating process applied The term ‘sintering’ arose from from which lamp filaments were
to shaped powders to provide strength geology where ‘cinder’ was used drawn. Scientific understanding of
by bonding the particles into a solid. to describe hardening of mineral how sintering occurred emerged as
Often, but not always, densification phases around geothermal vents. atomic diffusion became accepted in
occurs during sintering. Surface Modern uses for sintering trace to the late 1940s. Predictive models for
diffusion forms the first sinter bonds the early 1800s and the fabrication the role of time, temperature, particle
without causing a dimensional of platinum crucibles for melting size, and green density emerged in
change. When heated to a higher glass. By the early 1900s, sintering a body of mathematical expressions
temperature, grain boundary diffusion was used to fabricate tungsten ingots by the 1980s [1,2]. Unfortunately, the
induces densification, grain growth,
pore rounding, and significant
property changes. The optimal
sintering conditions depend on the
material and particle size, realising
excessive heating leads to a loss of
properties and even swelling of the
component. Beyond classic textbook
materials, sintered materials often
rely on intentional grain boundary
segregants, including liquids, to retard
grain growth or accelerate sintering.
Within the confines of Additive
Manufacturing, it is important to
differentiate between the sintering
process that is used to densify parts
created by metal Binder Jetting and
Fused Filament Fabrication, and the
Laser Powder Bed Fusion of metal
powders, often erroneously referred
to as a variant of ‘laser sintering’, in Fig. 1 Scanning electron micrograph of spherical bronze particles to illustrate
which a very different melting process sinter neck formation between contacting particles prior to significant
occurs. densification
All you need to know about sintering | contents | news | events | advertisers | website | e-newsletter |
models assume ideal conditions and powder chemistry and particle size. For loose powder, such as
often ignore significant parameters Thus, in spite of the availability of a that used in sinter-based Additive
such as heating rate and atmosphere diverse range of binders and shaping Manufacturing, sintering follows a
reactions. With modern instrumenta- approaches, sintering cycles are geometric progression consisting of
tion it is clear that most sintering often similar for seemingly different four stages:
occurs during heating, not during the forming routes.
• Contact formation – Weak
hold at the peak temperature. Formally, sintering is a thermal
adhesive forces pull the particles
The study of sintering spans a treatment applied to particles
together
broad range of materials. In spite of to increase strength by bonding
its broad use, the sintering trajectory particles to one another. The bonding • Neck growth – Initial bonding
is essentially the same for most occurs by atomic motion with a at particle contacts by surface
materials (polymers, ceramics, net reduction in surface energy as diffusion
metals, composites, minerals and evident by surface area loss. It is • Pore rounding – Growing necks
intermetallics). Thus, in teaching possible to induce densification merge to form tubular pores
sintering behaviour, a broad range of along with bonding, but a change • Pore closure – Final stage grain
examples and materials is available in density is not always observed, growth with closed pores
to help understand the general especially for larger particle
behaviour. sizes. Filters and bearings are After initial bonding, the pulling
Industrial sintering cycles are examples of sintered products where together at particle contacts, due to
defined by several parameters – densification is intentionally avoided. capillary stress, results in shrinkage
green density, particle size, heating Sintering is enhanced by smaller and densification. In turn, shrinkage
rate, peak temperature, hold time particles, higher temperatures and induces formation of new particle
and process atmosphere. Pressure is certain grain boundary phases. contacts that further bond the
applied in some cases, but pres- Although liquid formation is common structure. For sinter-based Additive
sureless sintering is predominantly during sintering, practically it is Manufacturing, the initial structure
favoured because of its significantly limited to less than about 15 vol.% corresponds to each particle having
lower cost. Further variations liquid. Larger amounts correspond five to six touching particles, termed
arise in the design and operation to semi-solid casting approaches the coordination number. As shrinkage
of the sintering furnace. The peak such as rheocasting. Total particle occurs the coordination number
temperature depends on factors such melting with electron beams, lasers, increases to an average of about
as the material melting temperature or arcs is not initial
After sintering, but a the
bonding, variant thirteen to
pulling together at fourteen
particle contacts, faces on each due to capillary stress, r
and particle size. The hold time at of casting.
in shrinkage and densification. Ingrain turn,at full density.
shrinkage inducesThus,formation
sintered of new particle
the peak temperature ranges from contacts that further bond the structure. properties Fordramatically
Additive Manufacturing, improve with the initial struct
a few seconds to a few hours. Time Aftercorresponds
initial bonding, to eachtheparticle
pullinghaving
together 5–6attouching
densification, particle dueparticles, contacts,
to an increase due in
termed to the
capillary
the stress, r
coordination
at temperature can be adjusted to The basics
in shrinkage of andsintering
densification. In
number. As shrinkage occurs the interparticleturn, shrinkage
coordinationbond induces
number formation
size increases
and number of
to an new particle
of average of abou
deliver equivalent thermal work; contacts
13–14 that
facesfurther
on eachbond theatstructure.
grain interparticle
full density. ForThus, Additivebonds.
sintered Manufacturing,
Theproperties
coordination the initial struct
dramatically impro
high temperatures require less corresponds
Atomic motion to
during each particle
sintering
with densification, due to an increase having 5–6
number touching
in the NC interparticle particles,
relates to thebond termedsize andcoordination
fractional the number of
time. Although the green body is results in
number. a loss
interparticleof surface
As shrinkage bonds.area
occurs the coordination
The coordinationdensity number number
f as follows: NC relates increases to an average
to the fractional densityof fabo
as
weak prior to sintering, after firing and13–14
surface energy.
follows: Temperature
faces on each grain at full density. Thus, sintered properties dramatically impro
it is strong, often competitive in controls the process. During
with densification, due to heating
an increase in the interparticle bond size and number of
𝑁𝑁𝑁𝑁𝐶𝐶𝐶𝐶 = 2 + 11 𝑓𝑓𝑓𝑓 2
properties with that attained via other at low temperatures, bonding
interparticle bonds. The coordination occurs number NC relates to the fractional density f as
manufacturing routes. Furthermore, at the contact points between
follows:
the structure shows little evidence particles, as pictured in Fig. 1. Density is the most common
Density is the most common measure 𝑁𝑁𝑁𝑁𝐶𝐶𝐶𝐶of=the 2of+degree 11degree 𝑓𝑓𝑓𝑓 2of sintering. It is a good predictor
of the initial particles. Atmosphere This image shows necks between measure the of sintering.
properties since most materials follow a power law relation between strength σ and
selection is guided by the material spherical bronze particles during It is a good predictor of properties
fractional density f:
chemistry and is a significant factor early sintering. As the necks grow, since most materials follow a power
for proper sintering. Density
there is the
is initially nomost common measure
densification. lawofrelation
the 𝜎𝜎𝜎𝜎 degree 𝜎𝜎𝜎𝜎𝑂𝑂𝑂𝑂 𝑓𝑓𝑓𝑓 𝑁𝑁𝑁𝑁of sintering.
= between strength σItand is a good predictor
Binders are routinely added to properties
Later, with highersince most materials follow
temperatures, a power
fractional density f: law relation between strength σ and
powders to facilitate shaping. The fractional
smaller density
particles f: times,
or longer
binders are waxes or other common wherepull
the particles σO together
is the strength
to fuseat full density. The exponent N is often from 4 to 6, depending
the material
into a dense structure sensitivity to residual pores.
that no longer
𝜎𝜎𝜎𝜎 =For 𝑓𝑓𝑓𝑓 𝑁𝑁𝑁𝑁
𝜎𝜎𝜎𝜎𝑂𝑂𝑂𝑂ferrous alloys, this means 15% porosity
polymers that can be removed during
heating to the sintering temperature fractional
shows evidence ofdensity)
the precursorlowers strength to 50% of the full density level (N ≈ 4.3). Besides
– they decompose at temperatures density,
particles. Indeed,other sintering
coarsening monitors include
during whereshrinkage, σO is the strength conductivity
at fulland hardness. These
far below the sintering temperature. where
sintering σO is the
parameters
results strength theatneck
link toseveral
in grains full size
density.
ratio; The that exponent
is,
density. The exponent N is often the diameterN is often
of from
the sinter
from 44tobond
6, dependin
between
Consequently, much of the sintering thelarger
times material
thansensitivity
particles Xthedivided
initialby tothe
residual
particleparticlepores.
diameter For ferrous
D , giving
to 6, depending on the material sensi- alloys,
the this means
dimensionless 15%
neck porosity
size ratio
cycle is independent of the binder fractional
size. Hundreds density)
and even lowers
thousandsstrength to 50%
tivity to∆residual of the full
pores. density
Forbodylevel
ferrous ( N ≈ 4.3). Besides
Shrinkage is the decrease in dimension L from the green size prior to sintering
density, fuse
of particles other sintering monitors
a single include shrinkage, conductivity and hardness. These
composition and component forming giving ∆Lto /Lgenerate
O. It is often given as aalloys,
percentage. this means Measures 15% porosity
such as (0.85
density and shrinkage
route, but it does depend on the parameters
grain. link to the neck size
relatively easy to perform versusfractional ratio; that
measuring is, the
density) diameter
neck size. lowers of the
strength
A related sinter
to bondisbetween
parameter densific
particles X divided
the change by the particle
in porosity resultingdiameter D, giving
from sintering the dimensionless
normalised neck
to the starting size ratio
porosity. If a
pore space
Shrinkage is theisdecrease
eliminatedinduring sintering,
dimension thenthe
∆L from densification
green body is size
100%. These
prior paramete
to sintering
are related
giving ∆L/2019 and one can be used to calculate
LO. It is often given as a ©percentage. the others.
MeasuresLtd such as5density
128 Metal Additive Manufacturing | Autumn/Fall 2019 Inovar Communications Vol. No. 3 and shrinkag
relatively easy
In most to perform
situations versus measuring
the sintered component neck size.
volume A related
is smaller parameter
than the greenisordensific
initial
50% of the full density level (N ≈ 4.3). (a) (b)

Besides density, other sintering moni-
tors include shrinkage, conductivity
and hardness. These parameters
link to the neck size ratio; that is, the
diameter of the sinter bond between
particles X divided by the particle
diameter D, giving the dimensionless (c) (d)
neck size ratio X/D.
Shrinkage is the decrease in
dimension ∆L from the green body
size prior to sintering LO, giving ∆L/
LO. It is often given as a percentage.
Measures such as density and
shrinkage are relatively easy to
(e) (f)
perform versus measuring neck size.
A related parameter is densification,
the change in porosity resulting from
sintering normalised to the starting
porosity. If all pore space is eliminated
during sintering, then densification is
100%. These parameters are related
and one can be used to calculate the (g) (h)
others.
In most situations the sintered
component volume is smaller than
the green or initial volume, while
mass remains essentially the same.
The density increase associated with
shrinkage (usually expressed as a
Fig. 2 Molecular dynamics simulation of sintering for two body-centred cubic
positive value) is often assumed to be
tungsten spherical particles. Initially the crystal planes are not aligned at the
isotropic. If mass remains constant,
contact point, so a defective region arises in the neck that becomes a grain
the sintered fractional density f
boundary. In this situation the images are taken during heating from a) room
depends on the initial unsintered
temperature, to b) 500 K, c) 1000 K, … in 500 K increments to h) 3500 K. At
fractional density fO and shrinkage
the highest temperature, evaporation takes place as the particles coalesce to
ΔL/LO as,
eventually form a single sphere. Initially the atomic motion is on the particle
𝑓𝑓𝑓𝑓𝑂𝑂𝑂𝑂
surface and later grain boundary diffusion is dominant.
𝑓𝑓𝑓𝑓 =
Δ𝐿𝐿𝐿𝐿 3
�1 − 𝐿𝐿𝐿𝐿 �
𝑂𝑂𝑂𝑂
For a high green density, such as Molecular dynamics computer saturation vibrational frequency
85% of theoretical (possible using simulations help visualise the atomic is near 1014 vibrations per second.
mixed particle sizes), a shrinkage motion associated with neck growth. As temperature increases, more
of 3% gives 93% density and 5.3% These simulations input atomic atomic motion occurs, evidenced
shrinkage gives full density. On the interaction potentials that govern by increased vibrational amplitude.
other hand, at a green density of 45%, atom motion during heating. Clusters Initially, surface diffusion is active,
the required sintering shrinkage is of atoms are used to form particles. where atoms move from convex
23.3% to reach full density. Generally Each atom follows an interatomic surface sources to grow the concave
the larger the shrinkage, the larger attraction-repulsion potential that neck. At the sintering temperature
the distortion during sintering. A mimics melting, thermal expansion, each atom changes position on
close look at sinter-based Additive and elastic properties. Atoms average six times per second.
Manufacturing approaches reveals separated by more than the equilib- Sintering visualisation is
density gradients in the green body, rium spacing are attracted to one possible as shown by the images in
leading to anisotropic shrinkage. another, but atoms closer than the Fig. 2. These pictures correspond
Other factors, including substrate equilibrium spacing repel each other. to tungsten particles heated to
friction and non-uniform heating, also Heat increases the atomic vibrational increasingly higher temperatures at a
contribute to sintered size variations. amplitude. During sintering the constant rate from room temperature
Neck profile since atoms move into the pores from

radius R the contact plane between particles,
allowing progressive particle
approach or shrinkage and formation
Grain
of new contacts.
D boundary
D It is possible to accelerate
X
sintering by adjusting the grain
boundary chemistry. One common
step is to form a liquid phase, since
atomic motion is hundreds of times
faster in liquids versus solids. Solid
diffusion involves the creation of a
vacant site for atomic diffusion and a
similar energy to ‘jump’ an atom into
Fig. 3 Outline of the neck size X and the particle size D (assumed spherical) and
the vacancy. In liquids, the amorphous
neck saddle point curvature R during two particle sintering. A grain boundary
atomic structure circumvents the
forms in the neck due to crystal misalignment of the contacting particles
vacancy creation energy. Thus, liquid
phase sintering is easier, faster
and widely employed in industrial
to melting. As temperature increases Such simulations show several sintering – by nature, humans are
the particles grow a neck, then aspects of sintering – atoms move, impatient.
shrink together. A grain boundary randomly, but that motion is biased
forms in the neck due to random over time by a progressive reduction
misalignment of neighbouring in interface energy. At first this is Atomic motion
crystals. These grain boundaries are by atom motion over the particle
critical to subsequent shrinkage and surface, termed surface diffusion. Sintering combines surface energy
densification. Evaporation is evident The overall action is to eliminate and high-temperature atomic motion
at high temperatures. For two surface area by neck growth. As to bond (surface diffusion) and densify
particles, the lowest energy configu- grain boundaries form between (grain boundary diffusion) particles.
ration corresponds to coalescence particles, grain boundary diffusion What happens at the contact between
into a single particle 1.26 times the emerges. It is grain boundary particles is replicated billions of
initial size. diffusion that gives densification, times throughout a component.
Thus, models for bonding of two
contacting particles give a glimpse at
the behaviour, realising the events are
replicated throughout a component.
Sintered density, % The idealised two-particle sintering
100 profile is shown in Fig. 3. The
1250°C spherical particles are D in diameter
42 μm titanium
with a neck X in diameter. Initially, the
95 neck contour forms a concave saddle
1200°C approximated by opposing radii of X
and the circle of radius R. Surface
90
energy reflects broken atomic bonds,
so the smaller radius is higher in
85 energy, generating a capillary stress
1150°C that pulls the particles together to
enlarge the neck. This capillary stress
80 is termed the sintering stress. It is
roughly proportional to twice the
surface energy (usually 1–2 J/m2)
75
0 30 60 90 120 150 divided by R. For a 10 µm powder, R is
nominally about 1 µm so the sintering
Sintering time, min stress is about 2 MPa. That stress
falls as the neck enlarges, but still
Fig. 4 Sintered density versus hold time for 42 µm titanium powder vacuum it is sufficient to pull the contacting
sintered at three temperatures [3]. Faster rates of densification (steeper particles together up to about 95%
slopes) are associated with shorter times and higher temperatures density.
At room temperature, there is Sintered density, %

too little atomic motion to induce
100
shrinkage or densification. However,
at the sintering temperature there ZnS sintering
95
is considerable motion. For steel or 120 min. at 1000°C
stainless steel, sintering requires 90 nitrogen
heating to a point where the material
softens. This is termed thermal 85
softening. Before significant bonding,
a powder compact has a relatively 80
low strength (in the 0.1 MPa range).
Because of the low strength, fracture 75
susceptibility is high during heating. 0.0 0.2 0.4 0.6 0.8 1.0
Defects as small as 10 μm enlarge Particle size, μm
to become cracks; these form early
prior to much necking. Differential Fig. 5 Sintered density versus particle size for zinc sulfide heated in nitrogen
shrinkage between thick and thin for 120 min. at 1000°C, illustrating the improved densification associated with
sections is a common difficulty, small powders
requiring slow heating rates to avoid
cracks. Sinter bonding improves
strength, but thermal softening at
with a 4 μm powder [4]. But 1300°C or too long a sintering time, the
high temperatures reduces strength
is required with a 9 μm powder, and combination of pore coarsening
sufficiently to allow densification.
1385°C for 31 μm powder. Smaller and grain coarsening results in
That is, first the particles bond with
particles respond to a lower sintering loss of density and properties,
no appreciable shrinkage (usually
temperature. termed over-sintering. Fig. 6 plots
by surface diffusion), forming grain
Due to grain growth during such behaviour for a tungsten alloy
boundaries at the particle contacts.
sintering, the final grain size is sintered at 1480°C. Optimal strength
The neck growth increases the
larger than the starting particle size. is attained with less than a two-hour
compact strength. Then, at higher
However, pore size is complicated. hold. Sintered stainless steel exhibit
temperatures grain boundary
Porosity decreases due to densi- a similar loss of strength with excess
diffusion gives densification as the
fication, but simultaneously pores sintering [4].
structure softens. Finally, remaining
coarsen to increase size by vacancy or The driving energy for sintering
pores collapse into spherical voids
gas exchange, reducing the number is small, typically less than 1 J/g,
that annihilate if they are not filled
of pores and pore surface area. With resulting in a slow process. For
with an insoluble gas. This occurs
too high a sintering temperature, some materials, such as WC-Co
late in the sintering cycle at high
temperatures where the component
is again weak due to thermal
softening
Sintering is faster at higher Strength, MPa
temperatures since atomic motion 1000
increases amplitude on heating.
A practical demonstration is given
in Fig. 4, where sintered density is 950 95W-3.5Ni-1.5Fe
plotted versus hold time for 42 µm 1480°C
titanium powder sintered at three
900
temperatures [3]. Prolonged time
adds to the densification, but the role
of temperature is dominant. Smaller 850
particles are helpful, since they have
a higher sintering stress and shorter
diffusion distances. This is demon- 800
strated in Fig. 5 for experiments 0 100 200 300 400 500 600 700
using different particle sizes of ZnS sintering time, min
sintered at 1000°C for 120 min. in
nitrogen [2]. Indeed, with a stainless Fig. 6 Over-sintering occurs as materials pass through the peak density and
steel powder it is possible to reach grain size combination. This plot gives tensile strength as a function of sintering
98% density after 120 min. at 1050°C time for a tungsten alloy heated to 1480°C in hydrogen for times up to 600 min
MPa with 23% elongation [11]; for

comparison, the industry standard
for metal injection moulded 316L
stainless steel is 450 MPa tensile
strength and 40% elongation.
Liquid phase sintering relies on
grain boundary wetting. Several
examples are well known – TiC-tool
steel, Fe-Fe3P, WC-Co, W-Ni-Fe,
Mo-Ni, Fe-Cu-C, stainless-boron,
Cu-Sn, and most ceramics. For
example, AlN is treated with Y2O3 to
form a fast diffusion grain boundary
phase. Indeed, covalent ceramics
such as SiC and Si3N4 only densify
when additives are employed to
form an amorphous or glassy liquid
phase on the grain boundaries.
Alloy powders liquid phase
sinter when heated to the solidus
temperature where liquid forms
Fig. 7 A 422 stainless steel doped with 200 ppm boron to enable full density inside the particles. This liquid
when sintered for 60 min. at 1320°C in vacuum. On cooling the liquid phase softens the structure sufficiently
solidified to form the second phase between the solid grains that the sintering stress quickly
pulls the particle to full density.
Temperature controls liquid
formation, as evident by the plot of
density versus temperature in Fig. 8
cemented carbides, this means boundaries during sintering. That for 40 µm D7 tool steel powder [12].
heating to a temperature where liquid liquid induced full density, without Densification occurs near 1250°C.
forms. Liquids that have solubility degrading properties. This is an alloy Hold time is a minor factor. This
for the solid accelerate atomic custom designed for sintering; boron supersolidus sintering approach
motion and facilitate rapid sintering. reduces the sintering temperature is applied to high alloy systems,
Upon cooling, the liquid solidifies by about 100 – 120°C. Table 1 shows such as tool steels, stainless steels,
to give a composite microstructure a few examples of boron treatments cobalt-chromium, and superalloys;
consisting of solid grains bonded to [5-10]. Equivalent 12 μm powder generally alloys based on iron,
one another with an interpenetrating without boron sintered at 1250°C nickel, cobalt, precious metals,
second phase, as evident in the gives a strength near 300 MPa and or titanium. Fig. 9 shows the
microstructure shown in Fig. 7. 18% elongation. The standard for microstructure for a 0.8% carbon
This stainless steel was doped with sintered 316L stainless steel doped M2 tool steel sintered at 1280°C in
boron to form liquid on the grain with boron is a strength of 520 10 min. using a nitrogen-hydrogen
Particle size Additive Sintering Sintering time Tensile strength Elongation

(μm) (wt.%) temperature (°C) (min) (MPa) (%)
12 none 1250 60 300 18
12 0.4 B, 0.4 Al2O3 1252 60 575 55
12 1.5 NiB 1250 60 491 36
45 0.5 NiB 1245 45 575 18
45 0.5 NiB 1280 90 480 38
79 0.5 NiB 1250 30 480 23
< 100 3.0 Ni-Mn-B 1280 60 776 37
Table 1 Comparison of 316L stainless steels and boron doping to induce liquid phase sintering
Sintered fractional density

1.00
0.95 D7 tool steel

40 μm
0.90
0.85
0.80
0.75
0.70
1180 1200 1220 1240 1260 1280
Temperature, °C
Fig. 8 Sintered density for a 40 µm prealloyed D7 tool Fig. 9 Microstructure after supersolidus liquid phase
steel powder versus peak temperature, showing how sintering a M2 tool steel containing 0.8% carbon. The
supersolidus sintering densifies rapidly once the solidus powder densifies in 10 min. at 1280°C using a nitrogen-
temperature is reached [12] hydrogen atmosphere
atmosphere. Supersolidus sintering smaller pores shrink. Fig. 10 plots As grain growth occurs, the grain
requires precise temperature control such behaviour using log-log scaling boundary area declines, leading to
because excess liquid causes for 4.5 μm iron powder sintering at slower sintering.
component distortion. 850°C [13]. Porosity decreases, grains
There are two categories of atomic grow, and after an initial transient
transport mechanisms – surface the grain boundary area decreases Control parameters
and bulk. Bulk transport along while the number of pores decreases.
grain boundaries causes shrinkage, The pore size enlarges progressively Of the several parameters that control
pore annihilation, and densification. even though densification reduces the sintering, temperature is dominant.
Surface transport processes, mostly total porosity and number of pores. Fig. 4 previously illustrated this effect.
surface diffusion, reposition mass on
the pore surface to smooth the pores
and reduce surface area, but do not
give densification. Such behaviour is Sintering metric
useful in forming filters. In certain 100
atmospheres (hydrogen doped with
water or a halide such as chlorine), porosity, %
pore rounding without densification
occurs by evaporation and condensa-
tion across pores. Otherwise, early grain size, μm
sintering is predominantly by surface
10
diffusion and later densification is by
grain boundary transport. The excep-
tions are amorphous materials, such pore size, μm
as glasses or plastics, that sinter by
viscous flow.
In sintering science, the pores
are assumed to be accumulations of 1
vacancies. Pores emit vacancies, just 1 10 100 1000 10000
like a helium balloon gives up gas. Sintering time, min
These vacancies are annihilated at
free surfaces and grain boundaries. Fig. 10 Log-log plots of sintering changes for a 4.5 μm iron powder sintered
Atoms move in the opposite direction for a long time at a low temperature, capturing the loss of porosity, increases
to fill the pores. Vacancies also in average grain size, and slight increases in average pore size [13]. There is
migrate between pores, leading to a large decline in the number of pores to accommodate the porosity decrease
the growth of larger pores while the and pore size increase
Shrinkage, % the shrinkage relation to time and

temperature is given in Fig. 11, where
12
the shrinkage data correspond to an
1900°C
10 exponent N = 3.
The factor C depends on the
1800°C
8 material chemistry and particle size.
If a phase transformation occurs,
6 such as iron from body-centred cubic
1700°C to face-centered cubic, then the rate
4 of sintering changes due to shifts in
0.78 μm AlN
diffusion rates, grain size and forma-
sintered in nitrogen
2 tion of new interfaces. This effect is
seen in Fig. 12 for Fe-2Ni heated at
0 10°C/min. through the body-centred
0 30 60 90 120 150 180 cubic to face-centered cubic phase
Hold time, min transformation (alpha to gamma). The
data were taken using dilatometry,
Fig. 11 Sintering shrinkage for 0.78 µm aluminium nitride doped with yttria,
where dimensions are measured
sintered in nitrogen at various time-temperature combinations. Initial
directly during sintering. In this case,
shrinkage is fast, but shrinkage rate declines during the isothermal hold
most of the shrinkage occurs in the
lower-temperature body-centred
cubic phase, slowing after the phase
change. However, steels require
Shrinkage increases with higher 𝐶𝐶𝐶𝐶 𝑡𝑡𝑡𝑡 𝑄𝑄𝑄𝑄 sintering in the high-temperature
𝑌𝑌𝑌𝑌 𝑁𝑁𝑁𝑁 = 𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒 �− �
temperatures, but the shrinkage 𝑇𝑇𝑇𝑇 𝑅𝑅𝑅𝑅 𝑇𝑇𝑇𝑇 face-centred cubic domain in order
rate slows with time. Such behaviour to adsorb carbon for strengthening.
is treated using models where the Here T is the absolute tempera- Thus, for many ferrous alloys the
monitor Y (such as shrinkage, neck ture, Q is an activation energy typical sintering temperature is
size ratio, surface area loss, or (proportional to the material’s 1150 – 1350°C.
densification) depends on hold time melting temperature), R is the Hold time at the peak temperature
t and absolute temperature T via the gas constant, and C is a material- is not a strong factor. Sufficient time
relation: geometry constant. An example of is required to ensure uniform heating,
Sintered density, %
Shrinkage, %
100
12
Fe-2Ni
4 μm 90
8
10°C/min
α→γ 0.5 μm alumina

4 80
sintered in air
5°C/min. to
1650°C for 10 min
0 70
400 800 1200 40 50 60
Temperature, °C Green density, %
Fig. 12 Shrinkage data taken during heating for mixed 4 Fig. 13 Demonstration of how green density impacts
µm Fe and Ni powders (2 wt.% Ni), showing significant sintered density. These data are for 0.5 µm alumina
slowing after the phase transformation from alpha (body- heated at 5°C/min. to 1650°C for a 10 min. hold in air.
centered cubic) to gamma (face-centered cubic) crystal The lowest green density corresponds a coordination
structure. The pure iron transformation is 910°C, but as number of less than 4 contacts per particle and the
nickel is dissolved into the iron, there is a progressive highest green density corresponds to a coordination
decrease in transformation temperature that is not number of 6 contacts per particle. The sintering
shown shrinkage averages 16.6%
Log (grain size, μm) Cumulative percent

100
1.6 sintering composition
1.5 Cu 850°C 80 W-Ni-Fe
TiC-Mo-Ni
1.4 BaTi03-TiO2
60 VC-Ni
1.3 Fe-Cu
1.2 40 Co-Cu
Sn-Pb
1.1
slope = 1/3
1.0 20 model
0.9
0
0.8 0.1 0.2 0.4 0.6 1 2 3
0.5 1.0 1.5 2.0 2.5 3.0
Log (sinter time, min) Normalised grain size, G/G50
Fig. 14 Logarithmic plot of grain size versus time to show Fig. 15 Cumulative grain size distribution for several
grain growth behaviour for copper during isothermal sintered materials. The results are compared to a Weibull
sintering at 850°C. The slope of the graph shows the distribution model where the normalisation factor is the
mean grain volume is a linear function of hold time median grain size G50 to collapse the results of various
studies into a single curve
but long times have diminished • 61.5 vol.% packing sinters to This says the median grain volume
impact. Indeed, with respect to 94.6% density. depends on the initial grain volume
properties, long sintering times are GO3, hold time t, and a temperature
A high packing density helps
counterproductive due to grain and dependent parameter K. As a
sintering as illustrated in Fig. 13. The
pore growth. Some industrial sintering demonstration of this behaviour,
sintered density is plotted versus the
cycles are very short. For example, 850°C sintering data for copper are
green density for alumina powder
electronic films are sintered in a flash plotted on a log-log basis in Fig. 14.
subjected to the same sintering cycle.
lasting only seconds. However, for bulk The slope of one-third corresponds
From a practical standpoint, if the
shapes, rapid heating induces thermal to G3 varying with t. Grain size is
green density falls below about 45%,
stresses that cause distortion. In metal important to several properties.
then it is very difficult to reach full
injection moulded 316L stainless steel, The sintered grain size distribution
density.
the dimensional scatter increased with is self-similar, meaning the distribu-
heating rate [14]. Thus, heating rates tion shape is the same no matter the
of 10°C/ min. or less are more typical. Microstructure trajectory median grain size. Example sintered
Green density is another processing gain size distributions are plotted in
parameter. Smooth particles improve Several microstructure parameters Fig. 15 for a wide range of materials.
green density. A lower green density change during sintering. Besides The size scale is normalised to the
makes sintering more difficult since neck growth and surface area loss, median grain size. The symbols are
there are fewer particle contacts. It pores round and coalesce while grains experimental measures from a variety
takes less net atomic motion to densify grow. Grain growth involves atomic of sintered materials, while the solid
a well-packed, high-coordination exchange across grain boundaries line corresponds to a fit; F(G) is the
A high packing density helps sintering as illustrated in Fig. 13. The sintered density is
number compact. Loose packing only
plotted versus the green densityand accelerates
for alumina powder on approaching the samecumulative
subjected to full sintering cycle. fraction of grains with
reaches aboutFrom sixa practical
to seven contacts
standpoint, if the green density falls
density. Pores slow growth since below about 45%, size
then it of
is G
very , where G50 is the median size
per particle. For spheres
difficult to reachanfull
idealised
density. they reduce the grain boundary area. (half the grains are larger and half are
packing reaches a coordination Hence, the slowest rate of grain smaller),
number of twelve, resulting in growth is during initial heating, when
Microstructure
improved sintering trajectory
[15]. An example there is little grain-grain contact. As 𝐺𝐺𝐺𝐺 𝑀𝑀𝑀𝑀
with 316L stainless steel powder parameters
Several microstructure change during sintering.
necks emerge and pores round, the Besides neck growth 𝐹𝐹𝐹𝐹(𝐺𝐺𝐺𝐺)
and = 1 − exp �𝛽𝛽𝛽𝛽 � � �
𝐺𝐺𝐺𝐺50
contrasts sintered density
surface area loss,versus
pores round and coalesce while grains
higher grain boundary area allows for grow. Grain growth involves
atomic
initial packing exchange
(1360°C for 60across
min. grain
in boundaries and accelerates on approaching full density.
more grain growth.
Pores slow growth since they reduce the grain boundary area. Hence, the slowest rate of
hydrogen): During This is a Weibull distribution with
grain growth is during initial heating, whenisothermal
there is little sintering, grain
grain-grain contact. As necks
emerge and pores round, growth occurs with area
the median grain β = -ln2 (or -0.6931), ensuring F(G)
• 66.4 vol.% packing sinters to the higher grain boundary allows for more grain growth.
volume (G ) increasing as follows:
3 = 0.5 at the median grain size when
99.1% During
density,isothermal sintering, grain growth occurs with the median grain volume (G 3)
G = G50. The exponent M reflects the
increasing as follows:
• 63.1 vol.% packing sinters to distribution dispersion and is usually
98.2% density, 𝐺𝐺𝐺𝐺 3 = 𝐺𝐺𝐺𝐺𝑂𝑂𝑂𝑂3 + 𝐾𝐾𝐾𝐾 𝑡𝑡𝑡𝑡 near 3.
𝐺𝐺𝐺𝐺𝑂𝑂𝑂𝑂 𝜃𝜃𝜃𝜃
Vol. 5 No. 3 © 2019 Inovar Communications Ltd 𝐺𝐺𝐺𝐺50 =| Autumn/Fall 2019
Metal Additive Manufacturing 135
3
This says the median grain volume depends on the initial grain volume 𝐺𝐺𝐺𝐺𝑂𝑂𝑂𝑂 , hold time t, and �1 − 𝑓𝑓𝑓𝑓
a temperature dependent parameter K. As a demonstration of this behaviour, 850°C
Grain size, μm Cumulative fraction of pores

𝑀𝑀𝑀𝑀
35 1.0 � 𝐺𝐺𝐺𝐺 � �
𝐹𝐹𝐹𝐹(𝐺𝐺𝐺𝐺) = 1 − exp �𝛽𝛽𝛽𝛽
𝐺𝐺𝐺𝐺50
30
Ni 900°C 0.8
25 Weibull
distribution experiment
20 0.6
15
0.4 ZrO2-3Y2O3
10 10°C/min. to 1600°C
10h hold
5 0.2
0
2.0 2.5 3.0 3.5 4.0 𝐺𝐺𝐺𝐺𝑂𝑂𝑂𝑂0.0
𝜃𝜃𝜃𝜃
𝐺𝐺𝐺𝐺50 = 0 1 2 3 4 5
Inverse square root porosity �1 − 𝑓𝑓𝑓𝑓 Pore size, μm
Fig. 16 Data for sintered nickel showing mean grain size Fig. 17 A demonstration of how the cumulative pore size
versus the inverse square-root of the fractional porosity. distribution conforms to a Weibull distribution using data
Such behaviour is characteristic of sintering, implying from yttria doped zirconia sintered at 1600°C
that if the starting grain size and porosity are known,
then the grain size evolution is simply a function of the
sintered porosity (density)
𝐺𝐺𝐺𝐺 𝑀𝑀𝑀𝑀
𝐹𝐹𝐹𝐹(𝐺𝐺𝐺𝐺) = 1 − exp �𝛽𝛽𝛽𝛽 � � �
𝐺𝐺𝐺𝐺50
Initially, grain growth is slowed Pores and grains are
𝜀𝜀𝜀𝜀 1/3
coupled to Effects of key sintering
by pores since vapour transport one another 𝑑𝑑𝑑𝑑during
= 𝐺𝐺𝐺𝐺 �sintering;
� thus, parameters
6
is relatively slow (evaporation and the pore size also conforms to a
condensation) so grain boundaries Weibull distribution. The cumulative Most applications for sintered metals
encounter a drag force from the fraction of pores F(d) larger than size are structural components requiring
pores. As a result, a relation emerges d depends on the median pore size attention to mechanical properties.
between sintered median grain size d50 and an exponent M. The corre- Sintered surgical stainless steel illus-
G50 and fractional 𝐺𝐺𝐺𝐺 𝑀𝑀𝑀𝑀 f,
𝐹𝐹𝐹𝐹(𝐺𝐺𝐺𝐺) = 1− exp �𝛽𝛽𝛽𝛽 � density
� � sponding distribution is expressed as, trates the key parameters and their
𝐺𝐺𝐺𝐺50
impact on properties. The common
𝐺𝐺𝐺𝐺𝑂𝑂𝑂𝑂 𝜃𝜃𝜃𝜃 alloy is 17-4 PH, formally designated
𝑑𝑑𝑑𝑑 𝑀𝑀𝑀𝑀
𝐺𝐺𝐺𝐺50 = 𝐹𝐹𝐹𝐹(𝑑𝑑𝑑𝑑) = 1 − 𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒 � 𝛽𝛽𝛽𝛽 𝛽 � � AISI 630. It is a precipitation hardened
�1 − 𝑓𝑓𝑓𝑓 𝑑𝑑𝑑𝑑50
martensitic stainless steel that gives
a good combination of strength and
Again GO is the initial grain size Again β equals -0.6931. Fig. 17 corrosion resistance [16-19].
(effectively the particle size) and θ plots cumulative pore size distribu- Pre-alloyed 17-4 PH powders are
is typically near 0.6. This relation is tion data for sintered zirconia available from 0.2 to 100 μm sizes,
invalid when the sintered material according to this relation. The solid with 10 to 20 μm being most popular.
reaches full density because grain line is the fit to the pore size data Usually the particles are rounded
𝐺𝐺𝐺𝐺𝑂𝑂𝑂𝑂 𝜃𝜃𝜃𝜃
growth𝐺𝐺𝐺𝐺50continues
= without a change using M = 2. The coupling of pores or spherical to enable good packing
in porosity. �1 Fig.−16 𝑓𝑓𝑓𝑓 plots data from to grain boundaries causes the pore to about 60% green density. For a
4.3 µm nickel powder sintered at size distribution to follow the same typical 15 μm powder, a hold near
𝜀𝜀𝜀𝜀 1/3
900°C𝑑𝑑𝑑𝑑 to
= reach
𝐺𝐺𝐺𝐺 � � a final density of 93% trajectory as the grain size distribu- 600°C during heating ensures binder
6
to show agreement with this equation. tion. removal. Sintering shrinkage starts
Because sintering results in a self- Thus, during sintering the about 900°C, so another hold near
similar microstructure we find the microstructure evolves, where that temperature is appropriate to
pore size d is a function of fractional the median grain size enlarges, remove oxides while pores are open
porosity ε and grain size G as follows: the number of grains decreases, for evaporation. Hydrogen is able to
porosity declines, but pores coalesce penetrate pores from the surface,
and enlarge. The microstructure is forming steam that egresses out of
𝜀𝜀𝜀𝜀 1/3 self-similar, meaning the distribu-
𝑑𝑑𝑑𝑑 = 𝐺𝐺𝐺𝐺 � � the body. Long hold times at the peak
𝑑𝑑𝑑𝑑 𝑀𝑀𝑀𝑀
𝐹𝐹𝐹𝐹(𝑑𝑑𝑑𝑑) = 1 − 𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒 6� 𝛽𝛽𝛽𝛽 𝛽 � � tions in grain size, grain shape, and sintering temperature are not produc-
𝑑𝑑𝑑𝑑50
pore size generally track the same tive, since most densification occurs
Grain growth leads to a pore characteristics independent of the during heating. For example, at 1320°C
size increase while porosity and the time-temperature, material, and the peak density is achieved within 10
number of pores decline. processing factors. min. Higher sintering temperatures
𝑀𝑀𝑀𝑀
𝑑𝑑𝑑𝑑
136 𝐹𝐹𝐹𝐹(𝑑𝑑𝑑𝑑)Metal Additive
= 1 − 𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒 � 𝛽𝛽𝛽𝛽 𝛽 Manufacturing
� � | Autumn/Fall 2019 © 2019 Inovar Communications Ltd Vol. 5 No. 3
𝑑𝑑𝑑𝑑50
Sintered density, % Sintered strength, MPa
100 1200
10 μm 17-4 PH
100 10 μm 17-4 PH
90 5°C/min, hydrogen, 60 min
800 5°C/min, hydrogen, 60 min
80 600
400
70
200
60 0
800 900 1000 1100 1200 1300 1400 800 900 1000 1100 1200 1300 1400
Sintering temperature, °C Sintering temperature, °C
Fig. 18 Plot of sintered density versus peak temperature Fig. 19 Sintered tensile strength for 17-4 PH stainless
for 10 μm 17-4 PH stainless steel steel heated at 5°C/min. with a 60 min. hold at various
peak temperatures
induce grain growth and evaporative with 1317 MPa tensile strength and As with other ferrous alloys,
loss of chromium and copper, 10% elongation (1172 MPa yield additives are effective in reducing the
compromising corrosion resistance strength) [16]. sintering temperature. Boron added
and strength. However, heat transfer Graphite vacuum furnaces are as nickel boride allows sintering to
in the sintering furnace takes several successful for sintering 17-4 PH. full density at 1260–1280°C. After
minutes, so a hold is needed to Graphite reacts with residual oxygen heat treatment to 52 HRC the tensile
obtain uniform shrinkage throughout to create a low partial pressure of strength is 1400 MPa with 7% fracture
the furnace load. The high thermal carbon monoxide. Chromium oxide elongation [17].
conductivity of hydrogen helps ensure is reduced by carbon monoxide when Sintered dimension uniformity is a
uniform heating. the CO partial pressure is maintained concern, especially with large shrink-
Strength increases with sintered at a low level, below about 100 ppm at ages. Dimensional variation arises
density, so understanding the temperatures over 1100°C. A similar from: anisotropic pore shapes in the
conditions for reaching at least 95%
density is a key concern. Typical
data for sintered density versus “Dimensional variation arises from:
temperature are shown in Fig. 18
for a 10 μm powder (heated at 5°C/ anisotropic pore shapes in the green
min. to temperature with 60 min.
soak) [18]. In turn, sintered strength
body, powder segregation in the forming
increases, as shown in Fig. 19. These process, thermal gradients in the
results rely on hydrogen sintering;
however, production atmospheres furnace, gravity (especially for larger
vary between operations and include components), sticking or friction with the
vacuum, hydrogen, partial pressure
hydrogen, argon, partial pressure substrate, and mass variations between
argon, argon-hydrogen, and nitrogen-
hydrogen. Argon is insoluble, so it
components.”
inhibits densification once pores close,
resulting in lower sintered density and principle operates in argon sintering green body, powder segregation in the
properties. Nitrogen forms chromium in a graphite furnace, but the argon forming process, thermal gradients
nitrides, resulting in loss of corrosion remains in the pores to inhibit final in the furnace, gravity (especially
resistance. Thus, high mechanical densification. For this reason, a low for larger components), sticking or
properties come from hydrogen or partial pressure of argon is an option to friction with the substrate, and mass
vacuum sintering, giving 99% density suppress evaporation with only a minor variations between components. As
and heat treated hardness of 42 HRC, impediment to final densification [4]. an example, consider rapid heating.
Standard deviation, % Conclusions

0.10
Sintering is a thermal process applied
to solid particles to bond, strengthen,
0.08 and possibly densify the particles. The
events responsible for sintering take
0.06 place at the atomic scale. Some liquid
is often formed during a sintering
14 μm cycle, but liquid phase contents are
0.04
316L stainless steel kept to a minimum, under 15 vol.%.
0.02 Thus, sintering is different from
sintered to 98.6% density
melting such as occurs with Electron
Beam or Laser Powder Bed Fusion-
0.00
based Additive Manufacturing. Liquid
2 4 6 8 10 12 14 16 18 20 22
phase sintering is similar to brazing
Heating rate, °C/min
the particles together, where the
Fig. 20 The standard deviation in component length (100 mm green size) for solidified liquid glues the solid grains
14 µm stainless steel powder sintered to 98.6% density by heating to 1385°C at together into a coherent and strong
various heating rates [14] composite.
Sintering occurs at high tempera-
tures where atomic motion is active
and the material is soft. At high
Heat transfer leads to temperature dimensional variation. However, those temperatures, surface energies are
gradients in the furnace and in the measures cannot correct for varia- sufficient to induce bonding by surface
component. The furnace centre tions introduced in the forming step. diffusion. Subsequently, densification
is cooler than the edge, resulting This article hints at the underlying occurs by grain boundary diffusion.
in gradients that induce different science explanation for sintering. At A high green density increases the
dimensions depending on position the atom scale the atomic motion number of bonds per particle to
in the furnace. Further, dimensional events are random, but the slight bias increase the attractive force for better
variation increased with heating provided by interface energy results sintering. Smaller particles have a
rate as illustrated in Fig. 20 [14]. in a progressive elimination of first higher curvature that determines the
These data are for a 100 mm starting surface area and later grain boundary capillary force known as the sintering
dimension formed using 14 μm 316L area. Component densification is a stress. The sintering stress acts to
pull the particles together. With small
particles the diffusion distances are
shorter, so they naturally sinter faster.
“Improved dimensional control requires Temperature is an important control
attention to several factors besides the parameter, and for most materials,
active sintering is observed close to
time-temperature cycle. Indeed, sintering the melting range. Long hold times
at the sintering temperature are not
is often just the messenger about useful and extended holds result in
variations occurring prior to sintering.” over-sintering. While densification
ends when porosity is eliminated, grain
growth continues and even accelerates
as porosity is eliminated. Thus, peak
powder, sintered at 1385°C. Likewise, by-product of this energy reduction. sintered properties are often found at
component mass variation, as often At the component level, shrinkage less than full density while grain size is
occurs in the forming step, is a occurs. Non-uniform shrinkage small. Note that additives are common
precursor to differences in sintered and dimensional variation is the in sintered materials, to either impede
dimensions between components by-product of nonuniform green body grain growth or improve densification.
[2,18]. and gradients introduced during Pore behaviour is an anomalous
Dimensional uniformity requires sintering. Improved dimensional part of sintering. As porosity declines,
uniform green bodies and repeatable control requires attention to several the average pore size increases, but
sintering cycles. Slow heating, factors besides the time-temperature the number of pores decreases. Both
uniform temperature, and sufficient cycle. Indeed, sintering is often just pore size and grain size take on self-
hold time to thoroughly reach the messenger about variations similar Weibull distributions. The role
temperature are key to reduced occurring prior to sintering. of atmosphere in sintering is involved;
active atmospheres accelerate [3] R. F. Wang, Y. X. Wu, X. Zhou, C. [12] R. M. German, “Computer Simu-
sintering and help attain high final A. Tang, “Debinding and Sintering lation of the Sintering Densification
densities. On the other hand, inert Processes for Injection Molded of Prealloyed Tool Steel Powders,”
gases become trapped in the pores Pure Titanium,” Powder Metallurgy Journal of Materials Synthesis and
to retard final stage densification. Technology, 2006, vol. 24, no. 2, pp. Processing, 1997, vol. 5, pp. 379-390.
Often, vacuum sintering with a partial 83-93. [13] R. Watanabe, Y. Masuda, “Quanti-
pressure (hydrogen or argon) provides [4] A. Bose, I. Otsuka, T. Yoshida, H. tative Estimation of Structural Change
a good balance between the several Toyoshima, “Metal Injection Molding in Carbonyl Iron Powder Compacts
factors of heat transfer, suppression of Ultrafine 316L Stainless Steel during Sintering,” Transactions of the
of evaporation and oxide reduction. Powders,” Advances in Powder Japan Institute of Metals, 1972, vol.
Structural components dominate Metallurgy and Particulate Materials 13, pp. 134-139.
the applications for sintered - 2007, Metal Powder Industries [14] G. J. Shu, K. S. Hwang, Y. T. Pan,
metals and electronic components Federation, Princeton, NJ, 2007, pp. “Improvements in Sintered Density
dominate the applications for 4.57-4.68. and Dimensional Stability of Powder
sintered ceramics. Both mechanical
[5] R. M. German, Metal Injection Injection Molded 316L Compacts by
and electrical properties are quite
Molding – A Comprehensive MIM Adjusting the Alloying Composition,”
sensitive to residual porosity, so high
Design Guide, Metal Powder Indus- Acta Materialia, 2006, vol. 54, pp.
sintered densities are mandatory.
tries Federation, Princeton, NJ, 2011. 1335-1342.
Dimensional control, reflecting an
ability to replicate final size with a [6] H. I. Bakan, D. Heaney, R. M. [15] E. A. Barringer, H. K. Bowen,
small variation, is a major challenge German, “Effect of Nickel Boride “Formation, Packing, and Sintering of
in sintering. Although dimensional and Boron Additions on Sintering Monodisperse TiO2 Powders,” Journal
scatter is often assigned to the Characteristics of Injection Moulded of the American Ceramic Society,
sintering step, in reality the source of 316L Powder Using Water Soluble 1982, vol. 65, pp. C199-C201.
scatter arises from poor control of the Binder System,” Powder Metallurgy,
[16] M. Shirooyeh, “High-Performance
incoming powder or loose control of 2001, vol. 44, pp. 235-242.
3D Printed Stainless Steel: A Metal-
the shaping step – effectively sintering [7] R. Tandon, R. M. German, lurgical Perpspective on 3DEO’s
is the messenger, but not the cause. “Sintering and Mechanical Properties Intelligent Layering,” Advances in
of a Boron-Doped Austenitic Stainless Powder Metallurgy and Particulate
Steel,” International Journal of Materials – 2019, Metal Powder
Author Powder Metallurgy, 1998, vol. 34, no. Industries Federation, Princeton, NJ,
1, pp. 40-49. 2019, on CD.
Professor Rand German is the most
[8] C. Tojal, T. Gomez-Acebo, F. [17] H. O. Gulsoy, S. Salman, “Micro-
highly-cited researcher in sintering.
Castro, “Development of PM Stainless structure and Mechanical Properties
He consults with firms in both
Steels with Improved Properties of Injection Molded 17-4 PH Stainless
Additive Manufacturing and Powder
through Liquid Phase Sintering,” Steel Powder with Nickel Boride Addi-
Injection Moulding, and serves as
Materials Science Forum, 2007, vol. tions,” Journal of Materials Science,
consulting editor for Powder Injection
534, pp. 661-664. 2005, vol. 40, pp. 3415-3421.
Moulding International. At San Diego
State University, his current experi- [9] J. Takekawa, “Effect of Additions [18] H. J. Sung, T. K. Ha, S. Ahn, Y. W.
ments are literally out of this world, of B and Al2O3 Fine Powders on Chang, “Powder Injection Molding
involving microgravity liquid phase the Densification of SUS316L Steel of a 17-4 PH Stainless Steel and the
sintering on the International Space Powder,” Journal of the Japan Society Effect of Sintering Temperature on
Station. of Powder and Powder Metallurgy, its Microstructure and Mechanical
2003, vol. 50, pp. 807-811. Properties,” Journal of Materials
randgerman@gmail.com [10] H. O. Gulsoy, O. Er, M. L. Processing Technology, 2002, vol. 130,
Berkem, “Injection Molded of High pp. 321-327.
Density 316L Stainless Steel for Bio [19] B. Julien, M. Ste-Marie, R.
References Applications,” Advances in Powder Pelletier, F. Lapointe, S. Turenne,
Metallurgy and Particulate Materials “Parametric Modeling of MIM
[1] A. S. Helle, K. E. Easterling, M. - 2011, Metal Powder Industries As-Sintered Properties of Stainless
F. Ashby, “Hot Isostatic Pressing Federation, Princeton, NJ, 2011, pp. Steel 17-4 PH and 316L Using a
Diagrams: New Developments,” 04.104-04.112. Statistical Model,” Advances in
Acta Metallurgica, 1985, vol. 33, pp. [11] Standard Specification for Powder Powder Metallurgy and Particulate
2163-2174. Metallurgy (PM) Boron Stainless Steel Materials - 2010, Metal Powder
[2] R. M. German, Sintering: From Structural Components, Standard Industries Federation, Princeton, NJ,
Empirical Observations to Scientific B853, ASTM International, West 2010, pp. 4.1-4.10.
Principles, Elsevier, Oxford, UK, 2014. Conshohocken, PA, 2016.
Analysis. Trends. Forecasts.
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| contents | news | events | advertisers | website | e-newsletter | Elnik Systems: Sintering AM parts
Metal Binder Jetting and FFF:

Considerations when planning a
debinding and sintering facility
for volume production
A new generation of Binder Jetting machines now promises to deliver
high volumes of parts at previously unimaginable speeds. Metal AM’s
Nick Williams interviews Stefan Joens and the team at Elnik Systems
LLC, a leading provider of industrial debinding and sintering furnaces,
about the reality of entering this field and the technologies and
equipment that are needed for the often underestimated processes of
debinding and sintering.
Batch debinding and sintering Elnik states that its system was Over the years there has been a
furnaces manufactured by Elnik the first all refractory metal furnace process of continuous improvement
Systems, based in Cedar Grove, New with partial pressure operation from in the company’s products, focusing
Jersey, USA, have over a period of 10 mbar to 800 mbar for hydrogen, in particular on laminar gas flow,
nearly twenty-five years become a nitrogen or argon, with laminar temperature uniformity and accuracy
common sight in Metal Injection gas flow via an internal retort to through its proprietary Accu-Temp
Moulding (MIM) facilities around the remove the second stage binder. This system, process control automation,
world. The company’s leading position shortened processing time from the hot zone and retort strength, and
in the MIM industry will, it hopes, also thirty plus hours which was typical at durability. An automatic cleaning
put it in a strong position to deliver the time, to around twenty hours. process for the binder traps and the
the industrial scale debinding and
sintering equipment that is needed
to process parts produced using
metal Binder Jetting (BJT) and
Fused Filament Fabrication (FFF).
These technologies are rapidly
gaining traction as a ‘second wave’
in the development of metal AM for
industrial applications.
Elnik’s involvement in MIM dates
back to the early 1990s, when BASF
launched its Catamold® feedstock
system. It was shortly after this that
the company commenced the devel-
opment of a ‘one-step’ debind and
sinter partial pressure furnace
specifically to meet the needs of the
growing MIM industry. The company’s
MIM 3000 furnace, launched in 1994,
provided a cost-effective alternative to Fig. 1 Elnik Systems furnaces installed at DSH Technologies, the wholly owned
the two-furnace technology commonly subsidiary of Elnik Systems that offers process development, consulting and
used at that time. toll debinding and sintering services
Elnik Systems: Sintering AM parts | contents | news | events | advertisers | website | e-newsletter |
Fig. 2 The Elnik/DSH team, from left to right: Bruce Dionne (Vice President of Operations, Elnik Systems), Claus Joens
(Founder and Chairman of the Board, Elnik Systems), Bryan Sherman (Project Manager and Chief Metallurgist, DSH
Technologies) and Stefan Joens (President, Elnik Systems)
vacuum pump, which are the areas Elnik as Vice President of Operations. metal components. Stefan Joens
that see the heaviest flow of binder, Dionne formerly served as Vice told Metal AM magazine, “We see
have enhanced ease of use and President & General Manager of US a wide range of knowledge levels
enable the recording of all process MIM producer Megamet Solid Metals through our work with AM-related
parameters for quality and auditing – later Ruger Precision Metals, customers at DSH Technologies.
requirements. LLC – where he served as Director of Companies that are developing
Today, more than 350 of the Operations. AM machines are generally more
company’s MIM-grade furnaces are DSH Technologies, a wholly-owned versed, as they have built teams that
installed worldwide, with the majority subsidiary of Elnik Systems that offers include metallurgists and material
in North America and Europe. They process development, consulting and science personnel, and have access
range from 1 ft3 (27 litres) up to 9 toll debinding and sintering services, to furnaces, but even here there
ft3 (234 litres) in useable volume, also saw management changes with are still gaps. We make a strong
meaning they can accommodate a the appointment of Bryan Sherman, effort to help from ground level and
wide range of production capacity. another experienced MIM profes- discuss the process steps related to
The company has recently gone sional, as Project Manager and Chief debinding and sintering.”
through some significant changes. Metallurgist. “Companies that want to adopt
In March this year, Stefan Joens took sinter-based metal AM technologies
over at the helm as President as part in-house and are completely new to
of a strategic transition, ten years There’s no ‘easy button’ the technology need to make sure
after he returned to the business when sintering AM parts they do their homework, or develop
that his father, Claus Joens, founded strong working relationships with
in 1969. Claus, as Chairman of the Outside of the Metal Injection leaders in this field. Debinding
Board, continues to be involved in Moulding industry there is currently and sintering aren’t black magic,
the business. At the same time, MIM limited awareness of the complex but one needs to be open minded
industry veteran Bruce Dionne joined realities of debinding and sintering to learn a new technology and not
assume there is an ‘easy button’.

This is where DSH Technologies
has an impact, with its ability to
provide support and education to
customers looking to learn about the
technology.”
Even the largest of industrial
companies can be surprised when
they discover that, in order to debind
and sinter parts created on high-
volume commercial binder jet AM
machines that might retail for around
$400,000, they may have to spend
double that on a full-size sintering
furnace that meets their needs.
Commenting on how potential
customers respond to this, Joens
stated, “Whilst polymer AM has
become hugely popular and
widespread thanks to its accessibility
and ease of use, with sinter-based
metal AM there is certainly a
misunderstanding of total equipment
needs and upfront costs. Debinding
and sintering equipment is as vital
to the process as the AM machine
itself and needs to be included in the
evaluations for capital equipment
costs. While we produce a wide range Fig. 3 This view of the DSH facility illustrates how additional facilities required
of furnace sizes at varying costs to to run a furnace, such as process gas supply, air, power, water cooling
meet any production need, often at systems, etc., involve expenses that can often go unrealised in an analysis
much less than double the cost of a
printer, additional facility expenses
such as process gas supply, air, and the number of parts that you trays are all aspects of the process
power, water cooling systems, etc., are looking to produce. One cannot that are not yet particularly efficient.
often go unrealised in an analysis. just look at the build box volume and The time needed to complete these
The path to helping a customer assume a furnace needs the exact steps needs to be analysed when
understand the total equipment cost same process volume. The type of understanding throughput of an AM
for Binder Jetting and FFF starts with parts one plans to fabricate, the system into a furnace.
education.” intended positioning of these parts
on process trays and the total part
size and mass all have an impact on The furnace supply chain:
Understanding furnace furnace volume requirements. Ideally, A bottleneck ahead?
capacity requirements to optimise equipment utilisation,
the furnace should be planned to Metal AM technology development
Key to efficient metal binder jet and operate once per day. From here, one and adoption is happening at
FFF production is understanding can calculate the output of an AM remarkable speed. Currently, this
production volumes, given the need to system and match it to the stacked is especially true of sinter-based
fill an expensive furnace. Commenting volume in the furnace. In some cases, AM technologies. The promise of
on how many ‘production-scale’ depending upon the parameters, it the imminent availability of new
binder jet AM machines might be may take more than one AM system high-volume binder jet systems from
required in order to fully utilise an to achieve this optimisation.” HP and Desktop Metal is driving
industrial MIM/AM furnace, Joens One often unspoken factor that technology awareness and lifting
stated, “To understand the size of increases turnaround time from the the fortunes of longer established
furnace that you require, a number of AM machine to the furnace is the suppliers, such as ExOne and Digital
factors need to be considered – the post-processing stage after a build Metal, who are themselves making
build box size of the AM machine, has completed. Depowdering and strides towards the full ‘industrialisa-
the size of the parts you are making, then staging the green parts on sinter tion’ of their binder jet technologies.
pricing down due to efficiencies in

the build process, but this in itself is
not the path to price reduction. For
true efficiency gains, there needs to
be standardisation and collaboration
with AM equipment manufacturers
on delivery schedules and expecta-
tions. Efficiencies can be gained in
times of high demand and we are
working toward being able to offer
these efficiencies and gains to our
customers via many ways, including
lean manufacturing and leveraging
volume purchases of products and
fabricated parts.”
Planning a metal Binder

Jetting production line
A prospective investor in a production

line for high-volume metal Binder
Jetting needs to fully understand
the facility infrastructure required
when installing an industrial vacuum
debinding and sintering furnace.
In many ways such a facility is the
mirror of a MIM operation, except
Fig. 4 A view of the molybdenum hot zone in a MIM 3045 series furnace
that the moulding machines are
manufactured by Elnik Systems
replaced by the Binder Jetting
machines. Of course, you don’t need
the tool shop, but instead you do
Given the formidable combined and debinding/sintering equipment, it need post-processing facilities. As
sales and marketing capacity of the will take communication and collabo- a guide, in order to start up a MIM
above companies, one can anticipate ration to successfully meet upcoming manufacturing facility, the rule of
that a significant number of binder jet market demands.” thumb is a bare minimum of $2
AM machine sales will soon happen, “With collaborative strategies and million investment capital for all the
in a relatively short space of time. Can a lean manufacturing approach to required equipment, plus at least
the MIM furnace supply chain keep standardised equipment packages, a year’s worth of working capital of
up? After all, this is an industry made there is no reason that the demands another $1 to $1.5 million.
up in large part of small- to medium- of the industry cannot be met in a Joens suggests that any start-up
sized businesses who are more used timely fashion. Without this collabora- company needs to consider the
to dealing with a predictable pattern tive approach, and without visibility following facility shopping list, in
of orders, booked with ‘reasonable’ of volume potential, customers will addition to a furnace, when thinking
lead times. So, could you buy a large, be left to source AM systems and of venturing down the path of begin-
industrial-grade vacuum debind and furnaces independently, ultimately ning to make metal binder jet parts:
sintering furnace or two ‘off the shelf’ leading to longer lead times and
• AM machine/curing oven/
for delivery next month? Probably not. potential bottlenecks in production.
depowdering equipment
Joens stated, “There is a lot of This same philosophy needs to be
speculation as to what the market applied in relation to ancillary equip- • Powder storage and manage-
will demand in terms of production ment manufacturers such as gas ment
capacity, in particular from the metal generators, water cooling systems, • Primary debinding system
binder jet industry. There is still powder suppliers, etc.” (where applicable)
volatility and manoeuvring among Commenting on whether the • Secondary stage debinding/
the leading players and it is hard to anticipated rise in sinter-based AM sintering furnace
tell how things will evolve. Since the will lead to a reduction in the cost of
• Water cooling system
successful growth of the binder jet such sintering furnaces, Joens stated,
industry is dependent on both the “A higher demand for equipment • Gas generators, or bottle supply
availability of Binder Jetting machines has the potential to drive equipment • Extraction system
Fig. 5 An Elnik 3045 series furnace ready for shipping to a customer
• H2 sensors (where applicable) come together it typically results in get five to seven years of life out of
• Facility cooling and heating long lasting equipment. Of the many molybdenum process trays, if not
hundreds of furnaces that we have more, depending on the total load
• Power supply (200–800 amp
made for the MIM market, 97% are being processed repeatedly,” stated
service depending on equipment
still in service today. The majority are Joens.
size)
running with 85–90% uptime, if not
• Mobile staging carts/worktables better.” Hot zones and retorts
• Quality control equipment How often hot zones and retorts need
• Secondary processing equipment Power consumption to be replaced is again down to total
(where applicable) Power consumption and cost, stated production volumes, a company’s
• Relationships with heat treat- Joens, is related to equipment maintenance regime, and sintering
ment service providers capability; a hydrogen all metal temperature. “The majority of our
partial pressure furnace uses a lot customers see five-to-seven years
Furnace uptime more power than a graphite furnace of life on these units. Some users
An industrial debinding and sintering running under nitrogen. find ways to need replacements
furnace is subject to extreme and after two years of processing. This is
demanding daily production cycles, Process trays typically a result of not removing parts
whilst at the same time needing to Furnace process trays – the trays that have fallen onto the refractory
offer a high level of availability to on which green parts are placed metal, not performing burn out runs
avoid production delays. Commenting for loading into the furnace – have regularly, overloading furnace trays,
on the reality of furnace uptime, a varying lifetime depending on consistently running loads that have
Joens explained, “Furnace uptime customer use. Extending the life of a very high level of binder, and using
depends on the quality of what is these items can be down to simple parameters outside of the recom-
being produced and how the end user working practices – as an example, mended limits. Conversely, some
runs and maintains the furnace. When Elnik flips its trays after each process customers have had retorts and hot
reliable components, good manu- run to ensure they stay straight for zones in their furnaces for more than
facturing practice and a strong team a longer time. “Most customers ten years.”
Fig. 6 A selection of MIM parts showing the range of shapes and sizes that can be manufactured by the technology,
typically to net shape. The smallest part here is a 316L stainless steel locking device for a spectacle frame hinge,
weighing 0.028 g and produced in volumes of more than 4 million parts a year. The largest part is a 316L tripod base
which weighs 260 g and is 65 mm high
Learning from the MIM staging, secondary operations, heat • Building strong vendor relation-
treatment and finishing processes. ships both pre- and post-part
industry
These technologies are also a great fabrication.
complement to the MIM industry as • Part handling techniques and
At the most basic level, metal Binder
they expand the niche that the MIM strategies throughout the facility
Jetting and FFF are simply MIM
industry already fills, but with the
without the tooling. This means that “In addition to PIM International,
benefit of potentially thicker cross
anyone looking to get into this area of the industry magazine, there are also
sections, larger parts and higher part
metal AM can relatively easily educate some well-known books available
complexity. Time will tell how these
themselves on best practice, markets, on MIM process-related topics.
technologies will compete, but for
materials and more from a very The science of binder removal and
now, they are great companions.”
similar but far more mature industry. sintering has been developed for many
Joens believes that there are a
A number of MIM companies are years – there is no reason to try and
number of critical lessons any AM
currently openly partnering with reinvent the wheel”.
part maker can learn from the MIM
binder jet AM machine producers,
industry:
bringing their crucial understanding
of sintering to the table. Initially, it • Effective plant layout to ensure AM design freedom versus
is logical that MIM companies will maximum efficiency of workflow gravity
lead the adoption of metal Binder and use of personnel
Jetting and FFF thanks to their Metal Binder Jetting and FFF come
• Understanding the proper
existing debinding and sintering with the promise of great design
production flow of how parts will
capacity. Joens commented, “As an freedom but, as with MIM, gravity
move throughout the production
AM equipment manufacturer, the MIM can get in the way when it comes
floor to ensure maximum uptime
industry is a great place to start as to sintering. As such, the design
the players know the debinding and • Setting up ancillary equipment restrictions imposed by the sintering
sintering processes very well. They needs for future expansion stage of the process need to be fully
are proficient at equipment use and • Proper facilities and equipment understood. Joens explained, “Design
extremely knowledgeable about part for secondary operations freedom is for sure the most exciting
aspect of metal AM. We are seeing Commenting on how DSH works customer better informed as to when
designs, sizes and cross sections with clients to develop an application and how to employ MIM and binder
that MIM could only dream of. With or a debinding and sintering cycle, jet technology to get the most out of
that, however, comes some of the Bryan Sherman stated, “We start by what the processes can provide.”
challenges. What is the ultimate assessing a company’s readiness Sherman also stressed that it is
cross-sectional thickness possible? and understanding of the technology. important to know if an application
What is the largest mass possible? Our desire is not to just provide requires maximum mechanical
What ultimately are the repeatable access to state-of-the-art equipment properties or if it is non-stressed,
expectations for shrinkage in the X, but to educate: we want to see our allowing a more strategic approach to
Y and Z dimensions? Are mechanical customers succeed! We then move processing in order to maximise the
properties going to be repeatable? to the science, evaluating the part cost/benefits for the end customer.
The list really goes on and on. Green the customer is looking to process “Understanding the differences in
density plays a big part in the achiev- and what materials they are using process and methodology to get to
able density of any part, be it metal – both in terms of metal and binder. the end part allows for customers
or ceramic. Keeping this density Thermogravimetric Analysis (TGA) and clients to more readily find
above 60% by volume will assist with and Differential Scanning Calo- profitable opportunities”.
good sintered densities. Gravity is rimetry (DSC) curves give detailed
an additional factor. Unlike MIM and insight into what is happening during
conventional ‘press and sinter’ Powder each stage of the process. This, Metal FFF for prototyping
Metallurgy, there is no compression combined with previous processing and low-volume part
step in the Binder Jetting or FFF experience and real-world produc- production
processes. This makes for inherent tion techniques, leads to robust
challenges when designing a part if processes that our customers can Back in 2013, when Bruce Dionne
the effects of shrinkage and distortion employ for the lifetime of a part’s was running Megamet Solid Metals,
are not well understood. While these production. This, of course, also I visited his operation in my capacity
are a few of the topics that many of the gives our customers more tools and as editor of PIM International. One
equipment manufacturers are working experience to rely on in the future, evening the conversation led to a
to resolve, we are far from really making them better, more efficient discussion of the viability of extruding
understanding sinter-based AM’s full parts producers.” MIM feedstock to make AM parts.
potential and full limitations.” It is important to understand Whilst it was more of a ‘blue sky’
Joens added, “There are ways the significant differences between conversation than a serious proposi-
to provide structural supports or AM production methods. Laser tion, the technology is now very much
setters for sintering, but these can Powder Bed Fusion, for example, a reality with Desktop Metal’s Studio
be expensive in high volume produc-
tion. Some companies also offer an
anti-sinter layer, but there are other
viable ways to achieve similar results. “It is important to know if an application
These are all issues that we have
helped companies understand through
requires maximum mechanical
discussions with our team.” properties or if it is non-stressed,
allowing a more strategic approach to
Consulting on process and
application development processing in order to maximise the
cost/benefits for the end customer...”
When it comes to the sintering
of metal powder parts, a specific
debinding and sintering cycle is
required in order to reach the required involves melting rather than System and Markforged’s Metal
densities and properties. This cycle is sintering the powder. “When X system, among others, and the
influenced by a number of factors that working with customers versed in arrival of BASF’s Ultrafuse filament.
include part size, the alloy used, wall other AM processes and production Commenting on how MIM
thickness, the volume of parts loaded methods, it is critical to review the feedstock-based AM technologies
into the furnace, and the position and science behind sintering. Such an have taken off, Dionne stated, “Nick,
spacing of these parts on the furnace approach lays a solid foundation I really love that you remember that
trays, etc. Variations in this cycle will from which to understand a part’s discussion! I always knew that the
impact on both dimensional repeat- metallurgy and properties. This sets metal FFF technology would evolve
ability and mechanical performance. realistic expectations and leaves the and eventually become a reality.
When I served as President of the office, light industrial area or even a Contact
Metal Injection Molding Association garage at home. This can, however,
[MIMA] I challenged the industry be problematic from the sintering Stefan Joens
to come up with ways to print MIM standpoint. The infrastructure Elnik Systems
feedstocks. At the time my motiva- needed to support a partial 107 Commerce Road
tion was to reduce time to market pressure atmosphere of hydrogen Cedar Grove
by minimising the design cycle and in a vacuum furnace – the accepted NJ 07009
using the printed parts for prototype process for the sintering of MIM USA
assemblies, and also to figure out stainless steels – is simply unviable
sintering cycles, furnace layouts for office or at home use.” Tel: +1 973 239 6066
and setter designs all in advance “So, while some AM machine sjoens@elnik.com
of the injection moulding tool being producers are offering an office-
delivered. What has evolved is way friendly sintering solution, it must www.elnik.com
more exciting and put the same be recognised that they are limited
ability in the hands of anyone with an in their ability to provide results
FFF machine.” similar to or approaching industrial
Dionne stated that one of the equipment. A part may look good,
drawbacks of current FFF technology but there will inevitably be a world
is that, for the most part, we are of difference when it comes to
seeing single-head builds, meaning mechanical properties. For the
only one stream of material is being production of fixtures, fittings and
extruded at a time. “In this case, it non-functioning samples, this may
is a great process for one off or very be fine, but for stressed end-use
low volumes of parts, prototypes components, careful consideration C
and experimentation. However, is needed,” Dionne concluded.

M
even this technology is evolving

as we are starting to see multi- Y
station machines. Additionally, the Looking ahead CM
technology allows for a truly 100% MY
enclosed internal honeycomb struc- For manufacturers of specialist

CY
ture, something that is impossible MIM-grade furnaces such as Elnik

with Binder Jetting without trapping Systems, the growth of ‘MIM-like’ CMY
loose powder. As the technology AM processes presents a range of K
evolves, we will continue to see new exciting opportunities. Beyond the

and exciting applications.” goal of selling furnaces to this new
sector, by sharing their experience
Comparing compact ‘workshop’ of debinding and sintering, and
furnaces with their industrial thereby avoiding the need to
counterparts ‘reinvent the wheel’, they are in a
Whilst office friendly FFF-based strong position to positively impact
metal AM systems are growing the industrialisation of Binder
in popularity, thanks in part to Jetting and FFF processes.
their cost and limited demand on For companies such as Elnik,
infrastructure, there are, significant which through its DSH operation
differences in the performance of can also offer toll debind and
an industrial vacuum furnace, which sintering services, further
can work with various atmospheres opportunities exist in supporting
and different levels of vacuum, companies whose projects do not
compared to a compact office or justify the investment in a furnace,
workshop-based furnace. Dionne or whose facilities do not have
stated, “Office-based metal FFF the necessary infrastructure. In
systems are proving to be an attrac- 2018, Elnik opened a second toll
tive proposition for those making a debinding and sintering facility
first step into metal AM, or for those in Waldachtal, Germany, that
with limited volume demands. The expanded its capabilities in this
purchaser wants something similar area. A further expansion of these
to the FFF plastic process that can services is, states Stefan Joens, a
be easily set up and operated in an distinct possibility.
INDIA’S
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INDIA’S
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5ththEDITION
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EDITION
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| contents | news | events | advertisers | website | e-newsletter | Velo3D: Support-free serial AM
Velo3D: How a ‘support-free’

Laser Powder Bed Fusion process
could remove roadblocks to
serial Additive Manufacturing
With its Sapphire machine and Flow build preparation software capable of
highly-controlled, virtually support-free Additive Manufacturing, Velo3D is
pushing the limits of what is possible with Laser Powder Bed Fusion (L-PBF).
Since launching its first machine in 2018, the California-based company has
seen success with a range of highly complex parts which would challenge
even the most experienced AM engineer. In this article, Zach Murphree,
Velo3D’s Vice President of Technical Partnerships, explains the key factors
which set the company’s process apart from the wider AM market.
There is a misconception in the This ‘taco shell effect’ is not the need for temporary structures
Additive Manufacturing world that unlike what happens when two that later require costly, labour-
Zach Murphree, Vice President of sheets of unrestrained metal intensive machining and grinding
Technical Partnerships at Velo3D, are butt-welded together. In AM, to remove. And it is this secondary
is on a mission to clear up. The however, any unrestrained metal post-processing – more than any
scaffold-like structures that everyone can lead to build failures, hence other manufacturing constraint
in the industry refers to as ‘supports’
are in reality, he says, anchors. They
are used to keep the layers of fused
metal powder from peeling up and
away from the previously-built layers
or build plate below, rather than to
support the layers above and prevent
their collapse.
“The term ‘support’ is really a
holdover from plastic printing,” he
told Metal AM magazine. “Here, you
need support structures because
you’re fighting gravity, and the
part would distort or even collapse
without them. With L-PBF, however,
you’re fighting the metal’s tendency
to curl upwards, especially at angles
of 45˚ or less. If you don’t anchor
these surfaces down, your recoater
blade will eventually smash into
them, damaging the workpiece,
the blade, and possibly even the
machine.” Fig. 1 Velo3D’s Sapphire Additive Manufacturing system
Velo3D: Support-free serial AM | contents | news | events | advertisers | website | e-newsletter |
Fig. 2 An impeller designed with standard supports (top left) and reduced supports (middle) for production on Velo3D’s
Sapphire Additive Manufacturing system
– that has been the thorn in metal associated with AM, which has to maintain their structural integrity
powder bed AM’s side since its very until now come with many caveats. using conventional L-PBF systems
inception. Geometric constraints might be (Fig. 2). In addition, Velo3D states that it
Whether they are supports largely eliminated, as well as worries is often able to build even very complex
or anchors, Murphree and his over warping, part orientation, and workpieces ‘right first time’, something
colleagues at Velo3D aim to reduce wasted support material. that few in the Additive Manufacturing
the reliance on them in metal AM. industry can claim.
Doing so will, it is expected, allow While Velo3D’s process has some
manufacturers to skip the lion’s share Reaching the goal of unique features, it, like almost all
of post-processing; they will no longer support-free AM powder bed AM processes, relies on a
need to use valuable time ‘taking bed of finely-atomised metal powder; a
down the scaffolding’ post-build. Velo3D isn’t quite there yet, stated pair of lasers; and a gas-filled, oxygen-
Build plates could also, the company Murphree, but it is close. The free chamber. As in the majority of
believes, become a thing of the past, company’s Sapphire AM system can AM processes, parts are built layer
by layer, from the bottom up, with a
recoater spreading fresh material
across the burgeoning workpiece at
“... reducing support structures could every step.
Explaining what is different about
allow the realisation of the much- Velo3D, Murphree stated, “For the
vaunted design freedom associated most part, our technology is based on
a much higher level of process control.
with AM, which has until now come Our company founder and several
with many caveats.” others here have extensive experience

in the semiconductor industry, and
they have leveraged that experience
to develop a far more capable AM
machine, one that no others can
if parts were to be made free to ‘float’ currently build support-free surfaces currently match in terms of beam
within a fully-utilised build chamber. at angles lower than 10˚ (often management, integrated metrology,
Most importantly, reducing support horizontally), as well as structures machine construction, our non-contact
structures could allow the realisation with large inner diameters that would recoater design and, especially, the
of the much-vaunted design freedom normally need to be tear-drop shaped build software. That’s key.”
Infinite control over finite Without Object Print Correction With Object Print Correction
elements
The processing algorithms within

Velo3D’s Flow software, Murphree
noted, are an order of magnitude
more advanced than those used by
most AM systems. This software is
able to accurately simulate the build
in advance; analysing, predicting,
and then compensating for potential
deformation long before manufac-
turing begins (Fig. 3). In addition,
rather than processing one layer at Incorrect Print Correct Print
a time, Flow looks at ‘several tens
of layers’ both above and below the Fig. 3 Object Print Correction (OPC) within Velo3D’s Flow software corrects
current one, detecting part geometry build deformation issues before the build begins. The simulation engine applies
on-the-fly and applying feature- counter-deformation to the part to ensure that the first build is a good build
specific routines wherever needed to
further optimise the build strategy.
This is somewhat similar to Finite
Element Analysis (FEA) software, The technology enabling SupportFree
Murphree stated, which uses implicit
modelling to analyse an entire Process Feature Specific Closed Loop Melt Non-contact
Simulation Processing Pool Control Recoater
workpiece at once. “If you’re going to
build the correct geometry, you need
to consider the complete geometry,
and focus your efforts on applying the
Software-based print Part broken to >20 Only for low angle No contact of metal
right processes in this larger context,” validation types skins parts
he says. “This is a big chunk of our
Pre-print deformation Unique recipe for Overcomes preocess Reduces recoater
‘first part, good part’ success ratio.” correction each type instability damage
The computing power needed to
achieve this FEA-like functionality
would likely have been cost- Fig. 4 This is the foundation to Velo3D’s SupportFree technology, which
prohibitive as little as five years ago, is a combination of simulation from Flow, in-process metrology, and its
but thanks to parallel computing and non-contact recoater
the use of very efficient software code,
Velo3D can solve ‘huge slabs’ of the
model simultaneously. This means
analysing thermal boundaries all each of these factors in its technology. oxygen levels to less than 10 ppm,
around the melt pool, then applying Using the same attention to detail and often fall below 1 ppm – roughly
an optimised mix of laser power, found in semiconductor fabrication, 1000 times better than the industry’s
beam positioning, and spot size to his team believes that it has reduced standard. We’ve found that an oxygen
fuse the metal without negatively or eliminated the process variables level of even 50 ppm affects the
impacting the surrounding area. common to L-PBF systems (Fig. 4). surface tension on the melt pool,
This last factor highlights another and has a dramatic impact on its
important difference between behaviour.”
Greater accuracy through Velo3D’s system and others, he says.
the elimination of process “For example, we have the ability to
variables align our lasers to within 50 µm or Monitoring and control of
less of one another at every single spot size
Even the best build software doesn’t layer. The result is far greater part
guarantee that the laser will go where quality, with no visible overlap or Murphree explained that control of
you tell it to. Build accuracy may be witness marks where the lasers have spot size in laser powder bed systems
affected by alignment issues, beam traded-off duties. We have a non- is crucial, explaining that even a 10%
quality and atmospheric conditions contact recoater and enhanced gas increase in the diameter of the spot
within the build chamber. Murphree flow, both of which serve to improve can decrease the amount of applied
states that Velo3D has addressed process stability. We also control the power at the melt pool exponentially.
“Left uncompensated, this can mean

98% material density instead of the
99.9%, fully-dense metals expected by
the industry. This might not sound like
much, but it’s actually a huge differ-
ence, especially for those producing
aerospace and power generation
components. The metal’s mechanical
properties can deteriorate markedly
as well, with unacceptable levels
of porosity as well as lack of fusion
between layers, a failure mode that’s
quite difficult to detect.”
Velo3D manages these variables
and more, he says, through gas-tight,
thermally-stable machine architecture
and continuous process monitoring via
a host of onboard sensors. Aside from
the basics such as chamber tempera-
tures and oxygen levels, data on
thermal lensing, scan-field distortion,
and other indicators of optical health
– what he calls the heart of any AM
system – are also collected, providing
complete in-process history of all part
builds as well as an opportunity to
further refine system performance.
“That’s been an important goal for us
from the very beginning and to learn
from all this data,” stated Murphree.
Fig. 5 The as-printed KW Micropower diffuser housing, top and bottom views Case study: KW Micropower
Inc.
Recently, Velo3D collaborated with

Florida’s KW Micropower Inc. to
develop a unique diffuser housing
for production by metal Additive
Manufacturing (Figs. 5, 6). Enrique
Enriquez, founder and President of the
business, stated, “I’d talked to every
AM company I could find and they all
told me the same thing: we can’t build
your part. Fortunately, at the last IMTS
show, a friend suggested I stop by
the Velo3D booth – and that changed
everything.”
Enrique’s diffuser housing is a
Ti6Al4V disk measuring approximately
25 cm in diameter by 10 cm high, and
contains a complex series of internal,
low-angle passageways for gas flow. It
is a critical component in a miniature
power generator that he’s been
working on for the past four years,
Fig. 6 KW Micropower’s generator is small enough to fit in a suitcase but and he will soon be exploring serial
promises to generate 30 kW of electrical power production of the device.
Fig. 7 Cross section overview and details showing support structures within the channels (left) if the diffuser housing were
to be printed by existing L-PBF platforms, versus how the Velo3D Sapphire system can print the channels support-free.
Machining the support structures in this specific part design would be incredibly complex.
When finding a manufacturer Carolina, USA, to inquire about finish bed AM systems to test the impact
who could produce the part, the machining several of the diffuser of Velo3D’s support-free process on
hurdle was the internal channels housing’s close-tolerance features. its post-processing requirements
and the fact that there was no way KAM has extensive experience in the (Fig. 8). Following testing, Thompson
to remove the hundreds of tiny fields of both additive and subtrac- stated, “With the Velo3D part, the
supports required by other metal tive manufacturing and is quite internal channels were clean – no
powder bed printers (Fig. 7). As familiar with Ti6Al4V. supports, just like Zach told me.
stated earlier, Velo3D’s process is The diffuser housing was In contrast, the part printed on our
nearly support-free. In addition,
due to the Sapphire’s high level of
process control, Murphree had few
concerns over building the part in “When finding a manufacturer who could
titanium, a difficult-to-process and
reactive alloy. He was also able to
produce the part, the hurdle was the
use the company’s Flow software to internal channels and the fact that there
improve Enriquez’s original design,
reducing its weight by 37% while
was no way to remove the hundreds of
improving its flow characteristics. tiny supports required by other metal
According to Murphree, the part
was built correctly on the first powder bed printers.”
attempt.
As with almost all additively
manufactured parts, the
component still required some machined on the KAM shop’s Mazak legacy equipment, as we anticipated,
post-processing following the build I300S 7-axis machining centre, required us to spend approximately
process. Murphree contacted Jim allowing Thompson to complete the forty hours on support removal and
Thompson, Director of Operations part in one operation. KAM also built clean-up of the surfaces afterwards.
for Keselowski Advanced Manufac- an aluminium replica of the part There was none of that with the
turing (KAM) in Statesville, North on one of its existing metal powder Velo3D part, nor were there any of
Fig. 8 Top left, Brad Keselowski, Founder & CEO of KAM, and Michael Mullen, KAM Engineering Manager, discuss the
differences between two builds of the KW MicroPower diffuser before machining. Bottom left, qualifying the diffuser’s
datum surface on MAZAK i300 Integrex Mill/Turn machining centre. Right: CNC machinist Colby Burgin checks the
diffuser dimensions for best fit of machining to built part, ensuring proper alignment of the part envelope with the
machine work coordinate system
the usual problems with supports Conclusion Contact

breaking loose and getting caught
between the cutter and workpiece, Following the successful build Joyce Yeung
possibly damaging both.” and finishing of his part, a pleased Director of Marketing
KAM’s President, John Murray, Enrique Enriquez stated, “The results Velo3D
added another key point: “Because have been totally amazing. We’ve joyce.yeung@velo3D.com
the Sapphire is inherently more logged thousands of test hours with www.velo3D.com
accurate than competing technolo- the generator, and hope to start
gies, parts come out of the machine sending prototypes out next year
closer to net shape. This means for evaluation. A device this small
you’ll need less machining time to is very sensitive to what they call
finish them. And as anyone who parasitic losses due to friction and
owns a metal printer knows, the raw imbalance; in order to compensate for
material itself is not inexpensive. that, you need to find ways of making
Comparing the Velo3D part with everything more efficient. That’s what
the one that we printed, I figure you Velo3D brought to the table. Because
could save an additional 10–30% on of their capabilities, we’re now able
material costs, plus the additional to do some amazing things that were
build time necessary to lay down all never expected out of a generator this
that metal, only to machine it away small. Their technology has opened
later.” up a world of opportunities for me.”
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| contents | news | events | advertisers | website | e-newsletter | AM in the oil, gas and maritime industries
New horizons for Additive

Manufacturing in the oil, gas
and maritime industries
The wide potential of Additive Manufacturing in the oil and gas and maritime
sector has come to be widely accepted, with the technology offering significant
advantages in terms of lead time, part weight, part count, higher levels of
geometric complexity and new material properties. However, in these safety-
critical industries, there remain some concerns regarding the quality of AM
parts. A Joint Industry Project (JIP), begun in January 2018 and consisting of
twenty partners, aims to deliver a new JIP Guideline on Additive Manufacturing
for this sector. Here, DNV-GL’s Harsharn Singh Tathgar and Berenschot’s Onno
Ponfoort report on the guideline’s development.
In January 2018, eleven companies a practical and economically viable guideline and of the Business Impact
began two seamlessly-aligned Joint alternative to existing production Model. We will also introduce aspects
Industry Projects (JIPs) aimed at methods. Therefore, the project has for further development in new Joint
delivering a JIP Guideline on Additive focused on delivering a guideline that Industry Projects.
Manufacturing (guideline) for the is in line with realistic business and
production of quality-assured metal manufacturing processes. To assess
additively manufactured spare parts in the economic benefits of AM over Participation of the full value
the oil, gas and maritime industries. current manufacturing practices, chain
By July 2019 this group had grown a highly detailed Business Impact
to include twenty partners, with the Model (BIM) has also been developed An important prerequisite for the
goal of developing the requirements alongside the guideline. success of this project was the
necessary (technical, documentation, In this article, we will give an participation of partners representing
roles, etc.) to introduce spare parts overview of the most relevant aspects the complete value chain (Fig. 1). In
produced by AM into these industries, of the project and of the initial Additive Manufacturing, the collabora-
and an accompanying economic outcomes, and share the set-up of the tion of multiple partners with expertise
model. The consortium aims to have
a practical guideline available by the
end of 2019.
The guideline will provide a Applications
framework to ensure that metal Regulations and requirements
components produced by Wire Arc
Additive Manufacturing (WAAM) and
WORKFLOW
Design AM build Post- Use & End of life

Laser Powder Bed Fusion (L-PBF) processing maintenance recycling
are manufactured according to Material
specifications, in a safe and repeat-
Process
able manner, addressing the unique
challenges related to AM.
From the beginning, the partners
Services
argued that AM should not only ITC, tools, testing, knowledge sharing
deliver parts that meet specifica-
tions, but that it must also present Fig. 1 The Additive Manufacturing value chain
AM in the oil, gas and maritime industries | contents | news | events | advertisers | website | e-newsletter |
parts subsea that are not qualified or

Operators Contractors Fabricators
certified.” In the oil and gas industry,
BP SLM Solutions ArcelorMittal therefore, having a framework for
Equinor TechnipFMC Voestalpine quality assurance is a prerequisite for
the adoption of Additive Manufacturing.
Shell IMI CCI Additive Industries This explains why some consortium
TOTAL Kongsberg University of Strathclyde partners which might otherwise be
seen as competitors are willing to
Siemens HIPtec
cooperate for the sake of developing an
Sandvik industry practice for the qualification of
Aidro AM components.
The project is organised via two
Immensa Technology Labs aligned JIPs as shown in Fig. 2. The
Vallourec objective of the Guideline Program,
managed by DNV GL, Norway, is to
Ivaldi
develop requirements necessary
Quintus Technologies to introduce components made by
Additive Manufacturing for the oil,
Table 1 The twenty consortium partners involved in the project gas and maritime industries and
related applications. The Toolbox
Program, managed by Berenschot, the
WPF Cost & ROI (Potential Benefits) Netherlands, is dedicated to part and
material selection, and the assessment
management
Berenschot
WP E Supply chain automation of the economic impact of adopting AM.

Project
WP A WP B WP C WP D Another core focus of this programme

Part selection Material Production & Database is the management of part production
& functional selection & finishing of of typical for case studies selected by the
drivers requirements parts parts
end-users.
Aligning these two JIPs creates
an iterative process. The drafts of the
WP1 WP2 WP3
Develop AM procedure AM Requirements guideline are used to standardise the
specification procedure Quality production processes of various parts.
management
requirements qualification assurance

DNV-GL
Project
The in-use experiences with the draft

WP4 Case Study - Threat assessment & qualification plan guideline are fed back into the develop-
ment process to revise and verify the
WP5 Process description & issuance of guidelines practicality and quality enhancement of
the guideline. In addition, insights from
Jan 2018 part production are used to further
Berenschot JIP improve the business impact model by
DNV-GL JIP benchmarking its performance against
real production costs.
Fig. 2 The aligned JIPs: Toolbox Program (top) and Guideline Program
(bottom)
Production of real world
parts
in specific processes and activities, • The availability of tools, testing
is essential. We use the value chain and industry expertise to ensure Via actual part production, the
model as a framework; this frame- technical and economic feasibility. consortium partners hope to ensure
work indicates a workflow which is the development of a high-quality
designed with three major Additive The consortium partners are guideline that is in tune with realistic
Manufacturing constraints in mind: shown in Table 1. Together, they manufacturing practices. A first round
represent the entire value chain, from of part production enabled the consor-
• The interdependence of design, part design to end-use, and from tium to assess all activities that need
material and process when material and process development to be monitored and qualified to ensure
engineering a part to post-processing and testing. To a complete guideline. A second round
• The framework and industry each of these partners, ensuring of production was used to assess the
requirements the part must quality is of utmost importance, with completeness, but also the contents of
conform to one stating that, “We will not use the guideline in terms of requirements,
quality-level indications and testing

requirements.
Nine different parts have been
produced and assessed during this
project using two different Additive
Manufacturing technologies. Four parts
were produced using Laser Powder
Bed Fusion:
• An Equinor impeller in Inconel 625

(Figs. 3-4)
• The same impeller in Ti-6Al-4V
(Fig. 5)
• A Kongsberg propeller blade in
titanium
• A Kongsberg crank pin in
Inconel 718
Five parts were produced using Wire

Arc Additive Manufacturing:
Fig. 3 Impeller for Equinor, designed by Eureka Pumps and built using an
• A Vallourec circulating head using SLM280 in Inconel 625
X90 low-alloy construction steel
(Fig. 6)
• A BP cross-over in Inconel wire, in
two versions: limited scale and full
scale (Fig. 7)
• A Kongsberg crank pin, using S700
low-alloyed wire
• A Technip FMC/Total-designed
crossover, using F22 alloy steel
Using real world parts is essential

in a project like this. Both the guideline
and the business impact model need
to be tested under conditions that
resemble real life situations. By using
real world parts, it is possible to assess
the variations between traditional
manufacturing processes and the
Additive Manufacturing process. These
variations are found along the entire
value chain, not only in the discrete
production phase.
Even when using a standard
and known part, redesign, material
selection and process selection come
into play when moving to Additive
Manufacturing. Often, the material
used for the additively manufactured
part is not the same as the material
that was used when milling or forging
the traditional part. Powder bed-based
AM will also require support structures
to be designed and built along with the
part, to ensure its correct orientation
and robustness. And more importantly,
the decision to use AM is often driven Fig. 4 The test set-up at Eureka Pumps (Courtesy Eureka)
Fig. 5 The impeller for Equinor, designed by Eureka Pumps, this Fig. 6 Circulating head for Vallourec. Designed by
time built on an Additive Industries MetalFab1 in Ti-6Al-4V Vallourec, shown as welded, during machining
process using Böhler X90-IG
by the possible functional benefits as per the requirements in the The development of the guideline
that AM can offer, requiring a redesign designated service context. A began by identifying all possible failure
of the part. These examples again framework is therefore needed in modes, where over 300 failure modes
indicate the interdependence of design, order to assess and document that were identified and discussed based on
material and process. relevant requirements are adhered industry knowledge and AM expertise.
Correct and precise information will, to. The goal of this guideline is The Failure Mode, Effects and Criti-
in such a situation, only be obtained to provide such a framework cality Analysis (FMECA) worksheet was
when the AM process can be refer- for additively manufactured modelled after the value chain set-up,
enced against a traditional process components. By combining it with and has proved to be a living document
that aims at delivering a similar other service designated standards, and a practical tool to ensure that all
part to meet industry standards. In a framework is made available aspects deemed critical have found
addition, the mindset of part owners which ensures that the component their way into the guideline.
and production partners is completely performs as intended, as well as
different when producing a real part that the unique challenges involved
that can be put to use in practice, in AM are assessed. Part classification
compared to conducting a ‘design The guideline will provide
exercise’. Of course, parts produced purchasers of additively manufac- The guideline offers a quality assur-
as design exercises can be tested, but tured components with guidance ance methodology for the selected
only case studies conducted using real on what needs to be communicated Additive Manufacturing processes
parts ensure full attention is given to and what documentation and and parts. Specific requirements for
all relevant aspects. quality to expect, and will also each activity, as indicated in the value
provide manufacturers with chain, are outlined. Parts are divided
requirements on what documenta- into three categories depending on
Developing a practical tion they need to produce and the consequence of failure: AM Class
guideline how to demonstrate integrity. This 1 (AMC 1) is intended for non-critical
standardised approach will create components, AM Class 2 (AMC 2) is
The safety and reliability of operations trust between purchasers and intended for less critical components
depends on having equipment, devices, providers of additively manufac- and AM Class 3 (AMC 3) is intended for
facilities and personnel that perform tured components. critical components.
Depending on the AM Class,

different assurance steps are involved
based on the AM technology used,
such as build process qualification
testing, production testing and part
qualification testing:
• All parts shall be manufactured

using a qualified build process. A
build process is qualified through
a defined Build Process Qualifi-
cation Testing (BPQT) procedure.
The purpose of the BPQT is to
prove and provide a baseline
that, when using a certain set of
essential parameters, a certain
quality is achieved
• Production testing is intended
as a control to ensure that the
manufacturing process produces
parts according to the qualified
build process not just once,
but also on, for example, the
second, tenth or twentieth build.
The extent of production testing
and type of tests carried out are
different for the different AM
technologies
• Depending on the criticality of
the part to be manufactured,
the part itself or a representa-
tive geometry may need to be
tested. This is due to the unique
possibility AM brings to produce
the material and geometry Fix. 7 A cross-over for BP in production at the AFRC Strathclyde University.
simultaneously. The methodology Produced via WAAM in Inconel 718 in shielded environment based on a BP
and extent of part qualification design
testing depends on both AM
Class and AM technology.
part produced for post-processing, with different diameters might
DNV GL has a long history of or the post-processed part for perform the same function and be
developing and issuing guidelines testing? The guideline offers value made of the same material with the
for a wide variety of manufacturing chain partners a common language same manufacturing process, but
technologies. For Additive Manufac- and an overview of topics, including vary in appearance based on the
turing technologies to meet existing minimum requirements, to support diameters given. DNV GL set out
standards is not an easy task, as often the handover of these activities. to produce a guideline that makes
specific production or testing regimen AM is a prime example of a it possible to obtain these benefits
as given in norms or standards do not digital manufacturing method, through slight variations where the
apply when using AM. The bridge that relying on multiple design iterations risk allows.
DNV GL’s new AM guideline will offer to get to high-quality parts. It is not
towards meeting these norms and a pure stage-gate process. Another
standards is practical and legitimate. aspect to bear in mind is that AM is Focus on benefits for
The activities indicated in the AM often used for its capacity to quickly business
value chain cannot often be carried and economically produce slight
out by one company alone. Handovers variations of similar parts, allowing As mentioned, the partners in the
apply, but what can the next actor in manufacturers and users to meet consortium also want to ensure
the value chain expect when taking precise demands. For instance, a that AM presents a practical and
over the design for production, the cross-over to connect two pipes economically viable alternative to
MARKET Customisation & Product performance

OPPORTUNITIES Personalisation & functionality
Time to Co-creation
market
PRODUCTION
EFFICIENCIES
Transportation Design &

& Distribution Engineering
Stock & Inventory Manufacturing, Assembly

& Post-processing
SUPPLY CHAIN
BENEFITS
Value chain Tooling & Support
architecture equipment
6
Fig. 8 The benefits AM can deliver to a business are commonly indicated by three categories, as shown above, using the
Business Impact Model (BIM)
current practices. The benefits AM oil and gas industry. The produc- ahead is received, but final analysis
can deliver are commonly indicated tion times for the cross-overs, for often leads to a decision not to exploit
via three categories: example, were a fraction of the the well. AM could enable tooling to
production time currently observed. be produced much closer to the date
• Market opportunities that can be Further, though many spare parts of the final decision, thus avoiding
obtained are kept in stock, sometimes even production of parts that are destroyed
• Production efficiencies that can in multiple locations globally, a without ever being used.
be achieved replacement for a broken part is often Amongst the parts produced
• Supply chain benefits that can be not readily available or carries a long while developing the guideline, other
realised lead time. The shorter production benefits of AM spare parts were
times offered by the AM of spare parts highlighted, such as lightweighting
The Business Impact Model helps can reduce downtime and loss of and improved functionality. The BIM
to determine which benefits to focus efficiency in production facilities. The is expected to help companies make
on and what economic impact AM can thruster blade and circulating head in well-founded decisions on whether to
be expected to have. The model can this project are further examples of adopt AM to produce a part.
be used to different levels of detail, parts offering these benefits.
ranging from a quick cost assessment In addition, spare parts kept
to get an indication of the unit cost in stock often become obsolete, Status of the guideline
price of one part, up to a full business but the building up and storing of
case including estimations and stock represents a major capital Aligned practices are essential to
investment assessments (Fig. 8). investment. By reducing inventory optimise the use of AM. The possi-
In line with the value chain set levels through the use of AM to bilities offered by the on-demand,
up of the guideline, the BIM model produce spares on demand, funds on-location production of quality
ensures awareness of all aspects may be freed up and used for more assured parts will have a huge impact
regarding the demand, design, profitable activities. Producing parts on the cost and efficiency of opera-
production, testing, use and main- on demand with short lead times also tions in the oil and gas industry. The
tenance of the AM part. The model makes it possible to avoid producing alignment proposed in the guideline
allows the user to get an indication of parts which become unnecessary in covers elements of quality control
the economic variance between AM the end; one of the project partners that go far beyond the part production
and traditional manufacturing and indicated that its investment in the alone; the guideline stipulates the
quantify the impact on the bottom line production of tooling for oil well organisation of a quality management
with a lifetime perspective. exploitation often begins before the system for the entire part production
The parts produced in the JIP final decision for exploitation has process, ranging from purchasing
demonstrate clearly the economic been made. Parts are produced to information, manufacturing proce-
benefits that AM can deliver in the begin exploitation as soon as the go dure specification and personnel
Fig. 9 A titanium propeller blade built for Kongsberg, based on a Kongsberg design, using an SLM Solutions L-PBF
system. Top left: the redesigned blade; top right: the build box with propeller and witness parts; bottom left: the nesting
plan; and bottom right: the end-use application
requirements, to HSE requirements standards, provided it can be demon- chain partners from three continents
and quality control procedures for strated that they meet or exceed the will be an advocate for the standards
feedstock, equipment and operator requirements of the referenced codes guideline offers the industry a basis
qualification. Rules for administering and standards, and the deviations are for aligned practices and common
delivery, traceability and operational duly documented and agreed upon use of AM in the oil and gas industry.
limitations are also included. between manufacturer and purchaser.
The technical requirements To initiate a common language
in the guideline cover pre-build while using a new and still developing Conclusions
requirements, build requirements, manufacturing technology, the
post-processing requirements and guideline enforces the use of the The JIPs has created a thorough
testing requirements. For testing, terminology defined by the ISO/ understanding of the benefits and
both destructive and non-destructive ASTM, such as in the 52900 standard the essential technical requirements
testing regimen are described. (Additive manufacturing – General which must be met to make use
The guideline brings AM closer into principles – Terminology). The of AM in the oil, gas and maritime
line with codes and standards that issuance of the guideline requires the industries. With a focus on two
are agreed upon in the industry. Full full acceptance of all partners in the manufacturing processes (L-PBF and
reference to ISO and ASTM standards consortium, assuring that all relevant WAAM), industry leaders experienced
is made, with the latest editions stakeholders in the industry under- the importance of describing the
applying unless dated references are write the contents and the practical demands of the industry in detail
given. The guideline does leave room usefulness of the document. The fact to ensure the quality output of the
to use other recognised codes and that multiple operators and supply production process. They were also
inspired by the design freedom AM Climate change and public opinion Authors
offers, triggering new functionality are forcing companies in this arena
and part assemblies not possible to to review and adjust their business Onno Ponfoort
produce with conventional manufac- practices. Additive Manufacturing Onno Ponfoort, Practice Leader 3D
turing practices. offers many opportunities to Printing at Berenschot Consulting,
On the other hand, the AM respond to that call; for example, is based in Utrecht, the Netherlands.
industry leaders in the consortium better designs can improve the He has been active in the field of AM
gained a full understanding of the efficiency of operations, while since 2002, and has published articles
importance of part quality and on-demand production can and wrote the first book on the
risk consciousness in the oil, gas decrease the number of obsolete business impact of AM: Successful
and maritime industries. Material parts and thus minimise material Business Models for 3D Printing.
properties requirements were usage and waste.
o.ponfoort@berenschot.nl
shown to be especially demanding. Digital manufacturing processes
www.berenschot.nl
Collaboration between industry can also support the emergence of
and AM experts opened the door to completely new business models,
Harsharn Singh Tathgar
unique designs for both end-parts allowing for new collaborations to
Harsharn Singh Tathgar, Senior Prin-
and witness samples for testing, as be undertaken and industry-wide
cipal Specialist, Materials Technology
shown in Fig. 9. solutions to be developed to limit
at DNV-GL, is based in Høvik, Norway.
The partners in the consortium the impact on our planet and its
As of 2012 he has been specialising
also concluded that additional natural resources. As such, JIPs
in technology evaluation, technology
Joint Industry Projects would be like these are not only a means to
qualification, product and technology
beneficial to further the adoption of develop a common framework, but
development, with a focus on Additive
AM in the oil and gas industry. These also a driver of sustainable business
Manufacturing for the oil, gas and
JIPs might cover other AM process practices.
maritime industries.
technologies and other materials;
focus on getting to standardised Harsharn.Tathgar@dnvgl.com
processes on specific activities like Acknowledgements www.dnvgl.com
non-destructive testing; or delve
into the supply chain developments The authors are grateful for the
associated with digital manufac- support of the JIP Program partners
turing processes. They are devel- and the contributions to the article
oping two new JIPs to begin in 2020 from Fabian Nullmeier (Berenschot)
with a number of partners, focusing and Ole-Bjørn Ellingsen Moe
on hybrid material production and (DNV-GL). Readers of this article
digital warehouse concepts. are invited to contact the authors
The oil and gas industry is in to discuss essential aspects of
the midst of a transformation in accelerating the acceptance of
which alternative energy sources Additive Manufacturing as a valid
are sought for and sustainable alternative for producing quality
business practices are demanded. assured spare parts.
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| contents | news | events | advertisers | website | e-newsletter | Redesigning for AM
Redesigned for Additive

Manufacturing: Serial
production of a new fuel swirler
for Siemens gas turbine
Whilst the principles of Design for Additive Manufacturing (DfAM) may
suggest ‘clean-sheet’ components are the best way to reap the benefits
of AM technology, many examples of redesigns have brought significant
performance and economic benefits. In this article, Ray Huff and Terry
Wohlers report on further success at Siemens in the use of AM for gas
turbine fuel swirlers, highlighting both the development process and the
evolving role of digital data in manufacturing.
Since purchasing Materials Solutions, the benefits of AM quickly, while higher firing temperatures in its
Worcester, UK, in 2016, Siemens making a strong business case for combustion chambers. The swirler
has been vigorously evaluating the new manufacturing method. is responsible for mixing air and fuel
conventionally-made parts as Siemens credits AM for enabling prior to combustion by the burner.
candidates for Additive Manufacturing
and driving new component design
with AM in mind. As early as 2012,
Siemens showed work it had done
to repair gas turbine burner tips
using AM technology. In 2017, the
company subsequently redesigned
its entire burner for manufacture by
AM, yielding a more functional part
with fewer manufacturing steps. This
application was extensively covered
in the article, ‘Siemens: Digitalisation
enables the industrialisation of metal
Additive Manufacturing at Finspång’,
published in the Autumn/Fall 2018
issue of Metal AM magazine.
Most recently, Siemens has rede-
signed another burner component,
bringing additive serial production to
its large flagship gas turbine product
line. The new part, a fuel swirler, fits
into the company’s SGT5/6-8000H gas
turbine engine. The part followed the
now-familiar workflow of redesign Fig. 1 Swirlers and burner assembly and their location in the gas turbine
for AM, which takes advantage of (Courtesy Siemens)
Redesigning for AM | contents | news | events | advertisers | website | e-newsletter |
Fig. 2 Conventional design of ten parts (left) consolidated into a single AM part (right) (Courtesy Siemens)
Conventionally, the swirler is made up high-temperature demands of the six hours of processing time per
of ten cast and machined parts welded application, the swirlers are made in swirler for the conventional design,
together. The part is an active service a proprietary, solution-strengthened not including the time for casting.
component with production demand of Inconel alloy. The core IP related to The AM version, on the other
more than 1,000 units per year. the AM redesign is in the integrated hand, requires only one hour in
control over the entire process post-processing. This consists of
chain. Everything from the powder depowdering, part removal by wire
Considerations behind the and machine parameters, to the EDM, removal of support structures,
redesign post-processing and heat treatment, and bead blasting. It also requires
has been developed specifically for CNC machining at the base of the
Siemens redesigned the swirler this engine component. part where it is later welded to
assembly by integrating vanes, a The conventional swirler design the larger burner assembly. After
shroud, and mounts into a single required many machining and printing, each swirler is individually
AM design, which is about 250 welding steps to produce and measured and uniquely marked for
mm (9.8 in) in length. To meet the assemble. This accounted for about serialisation.
Fig. 3 Swirler redesigned for production by metal AM (Courtesy of Siemens)
| contents | news | events | advertisers | website | e-newsletter | Redesigning for AM
Fig. 4 Burners printed in an array of sixteen parts on a Laser Powder Bed Fusion machine (Courtesy of Siemens)
A focus on key value team reduced the print time by rated with Siemens Digital Industries
33% over standard settings. With to capture digital data along the
drivers
optimised build settings, a full entire process chain, from concept
build takes up to a hundred hours. development to serial production. A
Siemens uses time, cost and digital twin of the swirler is available
Siemens is currently running more
performance as the value drivers at every stage of development,
than forty metal AM machines – all
when choosing which parts might and continually updates as new
Laser Powder Bed Fusion – across
be produced by AM. In the case data informs design and process
its locations, with twenty-two in
of the swirler, the principle driver changes.
operation at Materials Solutions.
was the time savings offered by The digital twin, which begins
AM and the fact that the entire with the CAD model, provides several
manufacturing process could now The power of software: benefits. For example, it is the
be done in-house. Time savings
Enterprise Resource basis for the printing process. After
were a consideration in each step of printing, parts are scanned, resulting
production. For example, Materials Planning and the digital
in a second digital twin, which is
Solutions has invested in automated twin
compared against the original CAD
depowdering systems from Solukon model. If any significant deviations
to shorten hands-on post- The company uses an Enterprise are found between the digital and
processing time. The AM-produced Resource Planning (ERP) system additively manufactured models, the
swirler is functionally identical and in combination with its Real Time process has the potential to update
cost-competitive to its convention- Locating System (RTLS) to track the model for a more accurate part
ally produced counterpart. parts through the various production if necessary. Each version of the
To meet production demand, steps. The system is connected to digital twin is stored and later used
sixteen swirlers are printed at one a production scheduling system, to generate machining toolpaths for
time on EOS M 400-4 quad-laser which is expected to include the accurate post-build machining.
Powder Bed Fusion systems. By facility’s industrial powder manage-
adapting build parameters at ment workflow in the future. The
individual regions of the part, the Materials Solutions team collabo-
Redesigning for AM | contents | news | events | advertisers | website | e-newsletter |
Part certification
Materials Solutions has also invested in its part certifica-

tion process. For Siemens industrial gas turbines,
Association for parts require ISO certification at minimum. Aerospace
Metal Additive customers are served by similar certifications from
Manufacturing
Materials Solutions. The facility is certified by the
National Aerospace and Defense Contractors Accredita-
tion Program (NADCAP). It also has AS9100 and ISO 9001
Guiding the future of
quality management certifications. The entire process
the metal AM industry
chain, including AM build parameters, is locked down and
‘frozen’, which is required by the certification process.
This ensures repeatability over the part’s production life,
with the possibility of building spare parts in the future.
The company required about six months to qualify
its first two AM machines for swirler production. As of
July 2019, these two machines were qualified, with two
more in the queue. Gas turbine parts with a less critical
function can be certified in as little as ten weeks.
Conclusion
What Is AMAM?
The Association for Metal Additive While parts fully designed for AM are often touted as the
Manufacturing (AMAM) is composed harbingers of change in manufacturing, parts at many
of companies that lead the direction of the metal additive OEMs can benefit from this ‘adapt for AM’ approach. Such
manufacturing (AM) industry. It is one of six trade production parts will not only save customers money,
associations that comprise the Metal Powder Industries but also help build confidence in AM. Wohlers Associates
Federation (MPIF), the world’s leading trade organization expects that in more heavily regulated sectors, such as
serving the interests of the metal powder producing and aerospace, mainstream use of AM for series production
consuming industries. is still some years away. Even so, Michael Gorelik of the
Federal Aviation Administration (FAA), has expressed his
Why Join? belief that the transition to safety-critical parts will occur
sooner than initially expected.
 Guide the future of the metal AM industry In the meantime, Siemens and its energy business are
 Interact with industry colleagues including leveraging design for AM more heavily to turn the rudder
competitors, suppliers, and more of manufacturing with innovative AM production parts.
Siemens already has more than thirty parts qualified
 Create and maintain industry standards for AM serial production, with plans to industrialise two
 Market the industry to the public hundred parts in the future.
 Develop activities such as publications and training

Acknowledgements
Who Can Join?
 Manufacturers of metal AM components The authors thank the team at Siemens for its support of
this article.
 Metal AM raw material suppliers
 Equipment manufacturers and service providers that Authors
support metal AM
Ray Huff and Terry Wohlers

How to Join Wohlers Associates, Inc.
Visit amamweb.org for a membership application and
Fort Collins
additional details on AMAM or contact Dora Schember at
dschember@mpif.org or by calling 609-452-7700 x 110. Colorado 80525
USA
METAL POWDER INDUSTRIES FEDERATION www.wohlersassociates.com
105 College Road East, Princeton, New Jersey 08540
Phone: 609-452-7700 • www.mpif.org
PM CHINA 2020
The 13th Shanghai International Powder Metallurgy Exhibition & Conference
March 24th~26th, 2020

Shanghai World Expo Exhibition Center
Convergence of
Cutting-edge Technology &
Products
Organizer
Tel: +86 20 8327 6369/6389 +86 4000 778 909

Email: pmchina@unifair.com pmchina@unirischina.com
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Understanding metal powder

requirements for Additive
Manufacturing: Views from the
industry
At the 2019 Additive Manufacturing Users Group (AMUG) Conference in
Chicago, Illinois, a panel was held to discuss requirements for Additive
Manufacturing systems. Despite the late hour of the panel and depth in the
week at which it was held, a formidable crowd organised themselves to hear
Ryan Dehoff of ORNL, Filip Francqui of Granutools and John Barnes of The
Barnes Group Advisors discuss the topic of powder in AM. In this article, the
panellists explore in more detail the differences in powder requirements
between AM systems.
During the 2019 AMUG conference in Powder origins and and either gas or water is jetted at
Chicago, held from March 31–April 4, characteristics the stream to break up the liquid
a panel discussion was organised into smaller particles. Physics
on the topic of powders for Additive Understanding how metal powders then drives the droplets towards a
Manufacturing. As panellists, our are made can inform an under- spherical shape, seeking a lower
motivation was to generate some standing of how they behave. Metal energy state, as the particles cool
discussion on powder requirements. powders are typically produced using and solidify. Characteristically, the
Requirements for parts flow down an atomisation process, whereby powders produced via atomisation
from the environment or system the metal is heated until molten have a Gaussian distribution for size.
they operate in and typically help
us to decide which manufacturing
process and material we will use
to meet those requirements; they
are liberating for our industry
because they simplify how many
actual choices we have to make in
producing a part and focus the mind
on what is truly important, versus a
rule of thumb.
We contributed data from our
experience in AM to test some of the
industry’s views on powder, with the
ultimate hope of improving quality
and reducing costs. In recent years,
the industry has clearly begun to
question some firmly-held beliefs
about powders, as indicated by the
questions we received from the Fig. 1 The 2019 Additive Manufacturing Users Group (AMUG) conference
audience. attracted more than 2000 international participants (Courtesy AMUG)
Powder requirements for AM | contents | news | events | advertisers | website | e-newsletter |
Powder size demand vs. yield

60% 1200
GA PA Demand
50% 1000
40% 800
30% 600
20% 400
10% 200
0% 0
<15 15-45 45-105 105+
Fig. 2 Ti6Al4V representative PSD for gas (GA) and plasma atomisation (PA) (in percent) vs industry demand [1]
Depending on what kind of atomisa- Due to the different atomisation Particle Size Distribution
tion is used, the morphology can be methods and derivations within the Fig. 2 shows a representative PSD
very spherical (gas or plasma) to very field, powder characteristics differ by for a titanium alloy for two different
granular (water), with a structure that process and alloy. Some of the more atomisation techniques. It also shows
is almost like coral. important characteristics are: the conceptual demand from the AM
Once the powders have been market emanating mostly from Laser
produced, they can be sieved and • Particle Size Distribution (PSD) Powder Bed Fusion (L-PBF) systems.
classified to separate them into their • Morphology You will note that the highest demand
respective bins or markets. This is • Spread and flowability does not correlate to peak production
when the next set of powder charac- yield for powder. The demand curve
• Densities
teristics begins to evolve, including highlights the large numbers of
the powder’s flow, spreadability and • Defects L-PBF machines and the perceived
apparent and/or tapped density. • Chemical/phase composition PSD requirements on powder, i.e.
the desire for the 15–45 μm range.
The imbalance in production capacity
and demand creates excess supply
for Electron Beam Powder Bed
Fusion (EB-PBF) and Directed Energy
100
Deposition (DED) powders, while

trying to match supply and demand
Cumulative percentage by area (%)
90
for the more commonplace L-PBF

systems.
80
Cumulative percentage by area (%)
The choice of the alloy system to

70
be atomised will also strongly affect

the yield of usable powders. Fig. 3
60
shows the particle size distribution

for several different metal alloys.
50
Through understanding the process of

how metal powders are made, we can
40
begin to appreciate the commercial

30
influences through supply and

demand that affect price. By uninten-
20
Alloy 1
tionally overspecifying powders, the
Alloy 2
price can be inflated without sound
10
Alloy 3
technical reasons.
0
Due to the wide range of solidifica-

0 10 20 30 40 50 60 70 80 90 100
tion behaviours in metal systems,
Powder
Powdersize (microns)
Size (microns) sphericity and size distributions
can vary widely from one atomisa-
Fig. 3 The effect of alloy on powder production efficiency or PSD [2] tion technique to the next. Water
A B C
Fig. 4 Representative morphologies obtained from water atomisation (A), gas atomisation (B) and plasma atomisation (C) [3]
atomisation (WA) produces very values from 0.73 to 0.96, where 1 Spread and flowability
non-spherical particles, whereas gas is perfectly spherical. In practical Spreading, flow and density
and plasma atomisation (GA and PA) terms, particles with a sphericity characteristics are affected by the
techniques produce more spherical calculation of > 0.91 are typically sphericity, size and size distribution of
powders (Fig. 4). There are other considered to be ‘spherical’. While it the powder. Our ability to understand
powder production methods, but we can be calculated, the idea of what what we need with regard to these
will discuss the most common. is ‘spherical’ still involves some parameters can be influenced by
subjectivity. conventional wisdom and not purely
Morphology Circularity and aspect ratio by physics or melt characteristics,
Sphericity is often discussed, but can also be used to describe the which affect spread, flow and density
rarely defined. Fig. 5 shows the sphericity or roundness of the requirements. Generally speaking,
range in sphericity attainable for particle. Fig. 6 shows the relative large particles flow better than
a metal alloy, where sphericity is fraction of ‘circular’ and uniform small ones; more circular/spherical
calculated using Sphericity=Ideal aspect ratio particles as a function particles flow better than less
Surface Area/Actual Surface Area. of production from atomisation. Not circular/spherical particles; and PSD
In Fig. 5, micro CT was used to all of the production has the same also has an effect. PSD can change
measure particles and the sphericity circularity or aspect ratio; this issue over the useful life of a powder lot
was calculated and shown for can reduce the saleable yield. once atomised, after each run in an
0.73 0.74 0.75 0.77 0.78 0.80
0.81 0.83 0.84 0.85 0.87 0.88
0.89 0.91 0.92 0.94 0.95 0.96
Fig. 5 Measurements of sphericity by CT [4]
Circularity Aspect ratio

1.0 1.0
C10 AR10
0.8 0.8
C50 AR50
Cumulative fraction
Cumulative fraction
C90 AR90
0.6 0.6
0.4 0.4
0.2 0.2
0.0 0.0
0.70 0.75 0.80 0.85 0.90 0.95 1.00 0.4 0.6 0.8 1.0
Circularity Aspect ratio
Fig. 6 Circularity and aspect ratio as a function of production [5]
AM system; the population of fines etc. [2]. It is perhaps more impor- index is influenced by powder
(< 15 μm) decreases, which improves tant to AM than Hall Flow, because population, but also by the energy
the flow characteristics. In addition, there are only rare instances where imparted on the population. As
environmental factors like humidity a circular orifice, like that used to seen in Fig. 7, a range of cohesion
are relevant. measure Hall Flow, exists in an AM can be measured through different
Flow is typically defined by the Hall machine. powder population characteristics,
Flow method (ASTM B213), where In some machines, forced gas but, as more energy is applied to
50 g of powder is placed in a funnel- is used to help move the powder. that population, the cohesive index
shaped cone and the time it takes Whether or not a powder spreads becomes the same. This phenom-
for the powder to vacate the funnel is mostly due to the interactions enon is possible due to aeration of
is measured. Lower values of the between the particles: the stronger powders.
required time indicate higher flow. those interactions, the worse the Other methods are also
Spreading on the other hand, can spreading. The strength of those employed to address how easily
be measured by different means, such interactions can be expressed by a powder spreads. The industry
as cohesive index, angle of repose, the cohesive index. The cohesive needs a test that reliably measures
this spreading ability, taking into
account factors such as humidity
or moisture. Coupled with the
environmental factors, it is already
observed that higher fractions of
45 Cohesive index fine powder fines oppose spreading and can
coarse powder create higher avalanche angles.
40 spray-dried powder What is acceptable? This would
35 then depend on the AM process and
machine being used.
30
25 Density
Density, in this context, is the
20 packing density of the powder,
not of the individual particles. It
15
can be described by the Apparent
10 Density or Tapped Density (ASTM
B212 or B527) and it is a proxy for
5
the bed in a Powder Bed Fusion or
0 Binder Jet (BJ) AM system. Skeletal
0 5 10 15 20 density gives the true density of the
Rotating speed (rpm) powder and can therefore be used to
evaluate the existence of entrapped
Fig. 7 Cohesive index for fine and coarse powder versus rotating speed [6] gas in the powder.
Powder As deposited
Porosity in
powder = 0.873%
Gas atomised
Porosity in
deposit = 0.117%
Porosity in
powder = 0.491%
Rotary atomised
Porosity in
deposit = 0.037%
Porosity in
Plasma rotated powder = 0.000%
electrode
Porosity in
deposit = 0.000%
Fig. 8 Atomised powder porosity and subsequent printed density [2]
Of the many factors that influence of porosity in powder particles from powders. PBF generally favours
density or packing, principal among different atomisation methods [2]. metals that are weldable; the
them are sphericity and PSD. By This entrapped gas survived the AM same principle that governs the
narrowing the PSD, the packing process and remained in the printed build process also has merit when
efficiency begins to drop. In fact, samples (Fig. 8); the solidification atomising. Atomising is a kinetic
a study conducted by Princeton rates involved are too fast to allow process allowing metastable phases
University [7] filled a 5-litre flask the gas to escape from the particles to form. For alloys which are heat
randomly with ellipsoids (M&Ms) 100% of the time. For fatigue-limited treatable, the powder chemistry
and spheres (gumballs). Ellipsoids applications, this most likely means may be correct, but the phase
filled 74% of the space on their own that a Hot Isostatic Pressure (HIP) content will be different. While this
versus spheres at 64%. While it is cycle will have to be performed to is unimportant in fusion-based
true that hand packing the spheres minimise residual pores or defects. processes like PBF, it is crucial in
will give you about the same results, Further to this line of thinking, other AM processes which do not
this will result in very slow recoating Carnegie Mellon University has melt powders to achieve density,
speeds. demonstrated that the HIP only such as Binder Jetting or Directed
compresses the gas bubbles, which Energy Deposition derivatives like
Defects regrow upon the addition of heat [8]. Cold Spray Additive Manufacturing.
Inherent in powder production The development of other powder
via atomisation is the presence Chemical and phase composition manufacturing techniques that
of entrapped gas during the The chemistry and phase composi- do not rely on melting would open
solidification process. Work tion of atomised powders can be up new material solutions for the
carried out by Oak Ridge National highly relevant and this explains ever-expanding technology space
Laboratory identified the presence why not all alloys are available as of AM.
t = 0.85 ms t = 4.30 ms t = 8.50 ms
t = 12.25 ms t = 14.95 ms t = 18.75 ms
Fig. 9 The effect of binder ejection on highly flowing, spherical powder [9]
Process requirements surface area to volume ratio and lower with different requirements whilst
activation energy sinter earlier than aiming for similar end results. It is
There are a diverse range of Additive larger particles. not possible to describe the powder
Manufacturing technologies that Within PBF, Electron Beam requirements as being identical for
create dense parts via different systems traditionally use a 45–105 µm each of these mechanical proposi-
means and therefore also have PSD, whereas most laser-based tions.
different requirements for powders, if systems desire 15–45 µm PSD. DED Ultimately, it makes rational sense
used. Seven AM methods are defined systems can tolerate an even wider that, in a system that employs a bed
by ASTM F42: range PSD because of the forced of powder, a consistent bed with some
gas delivery. In addition, the PSD minimum density requirement is a
• Powder Bed Fusion (PBF) and powder size can have a strong good thing; and yet we take a lot of
• Directed Energy Deposition (DED) influence on the as-built surface finish different approaches to creating that
• Binder Jetting (BJ) of the final part. Within powder bed bed, without seeing huge differences
technologies, many different methods in the resulting part. This is partly
• Material Extrusion (ME)
• Material Jetting (MJ)
• Sheet Lamination (SHL), and
• Vat Photopolymerisation (VP).
“Ultimately, it makes rational sense that,
Of these seven forms, PBF, DED, BJ
in a system that employs a bed of powder,
and ME can use metallic particles. a consistent bed with some minimum
Even within a category, powder
needs can be different (for example,
density requirement is a good thing; and
DED can use blown powder melt or yet we take a lot of different approaches
a cold spray solid state process).
Both PBF and Binder Jetting require to creating that bed, without seeing huge
powders to be moved from a hopper
storage unit and spread across a
differences in the resulting part.”
build plate. It is preferable to create
a consistently dense bed. Binder
Jetting and ME achieve part density of distributing metal powders are fed by the recent movement toward
via sintering, which puts additional used – rollers, rakes, dosing wheels, ‘highly flowing’ powders. Highly
requirements on powders, where recoaters coupled with gravity feed or flowing powder, by definition, requires
smaller particles with a higher cartridge charge – all of which come little energy to induce it to move.
Fig. 10 Powder motion during PBF of flowing metal powder [10]
This also means that it requires little rapidly to thousands of degrees as 20% of powder particles strongly
energy to force the powder particles the laser couples with the metal. affects powder ‘cohesiveness’)
to move out of the desired position; Immediately, the gas in the bed, which • Smaller particles allow finer
in both PBF and Binder Jetting, the comprises at least 30% of the volume, resolution of part dimensions &
energy applied by a laser or a binder is instantly heated and, as the metal surface finish, but may preclude
jet print head may cause the powder melts, metal vapours are produced, the ability to spread
bed to be disrupted before it has been which also promote subtle chemistry
consolidated (Fig. 9). changes as higher vapour pressure • Powder ‘spreadability’ can
In PBF, similar phenomena are elements evaporate preferentially. The determine whether a powder
seen. Fig. 10 closely mimics what was combination of these events can eject can be successfully used in
seen by ND Parab et al [9] in Fig. 9. In the powder upward. a particular machine, but
this study, powder particles from the Despite these dynamics, the acceptable ‘spreadability’ varies
bed were tracked as they were ejected process works. However, there exist between machines
from the melt area. The velocities at opportunities for defects stemming
• Particle morphology (i.e.,
which they are ejected can also be from lack of fusion or keyholing, but
circularity, aspect-ratio, surface
quite high; the authors cited ejection also from the atomisation process
roughness) also affects flow and
speeds in excess of 10 m/s from the leaving entrapped gas in the powder
spreading behaviour, but usually
melt area. particles. Each of these could create
to a lesser degree for AM powders
Within powder bed systems like additional costs to remedy.
than the size of the smallest 20%
PBF and Binder Jetting machines, the
of the powder
systems themselves have a need to
move powders from a storage system Technical summary
• The addition of a machine- and
and spread them onto as wide an area alloy-specific bulk powder
In this article, we have covered
as possible. This area is then the limit ‘index’ test, as a surrogate
a range of technical issues and
of the size of the part that can be built for spreadability, may allow a
pointed out some inconsistencies
in one session. In Binder Jetting, the wider range of powders to be
in what might be desired versus
physics and mechanics are slightly ‘accepted’/‘qualified’ for specific
what is actually required. End-part
at odds with each other. Ultimately, AM machines
requirements should be paramount;
small, non-spherical particles are
how these requirements are met • High flowability and spreadability
required for sintering; however, these
is a combination of process and can adversely affect the ability to
characteristics oppose the mechanics
materials, as it has been with every create a consistent, maximum-
of flowability.
other manufacturing technology. density powder bed
In PBF, the Electron Beam process
It is important to understand the
already uses larger particles, but also
difference between a requirement and • Ellipsoidal particles would have
employs a pre-sinter to connect the
a rule of thumb: better and more consistent
particles together, thus minimising
natural or random packing
ejection by melt dynamics. In laser- • Particle Size Distribution is widely
based processes, once the powder recognised as an important • Atomisation is a way to make
bed is created, gas flows across the parameter affecting how well metal powder, but not the only
surface and local temperatures rise powder spreads (the smallest way
• The choice of powder should be understanding what is ultimately References

matched with the AM process – it driving powder behaviour, then what
is not a case of ‘one size fits all’ is driving needs, goes to influencing
[1] Unpublished work, J. E Barnes &
cost. Over-specifying can be just as
Of course, we are not implying that K. Rogers Ph.D., 2019.
bad as under-specifying.
atomisation is not the most effective The process and powder [2] “Characterization of Powder for
way to make metal powders, as most relationship is clearly key. Further Additive Manufacturing”, R. Dehoff, M
of the industry is facilitated to do characterisation so that we, as an Bauza & E.C. Santos.
so. What we are asking is whether industry, can better understand those [3] Powder Production Training by
further cost-effectiveness can be interactions, was a common theme of The Barnes Group Training LLC
achieved by truly understanding the panel discussions.
requirements to make a part via AM, [4] Unpublished data, J.E. Barnes, K.
We can borrow from what other
keeping in mind there are currently Rogers Ph.D., 2018.
industries have learned. The field
seven AM technologies. Simply using of Powder Metallurgy has certainly [5] Unpublished data, Wayne King
more of the PSD, for example, could gained a lot of knowledge, as has Ph.D.
improve the cost-effectiveness of have pharmaceuticals. However, [6] “Rheological behaviour of
atomisation. There are a wide variety AM processes are different than β-Ti and NiTi powders produced
of methods to produce powders and prior press and sinter techniques, by atomisation for SLM produc-
particles. and metal powders have significant tion of open porous orthopedic
Having dense, defect-free differences from polymers; these implants.” Yablokova, G., Speirs,
particles of the right chemistry, both sound like simple statements, but M., Van Humbeeck, J., Kruth, J. P.,
in terms of elements but also phase it can be confusing to know what Schrooten, J., Cloots, R., ... & Luyten,
content, would seem highly desirable. information and data from other J. (2015). Powder Technology, 283,
The ability to pack well randomly industries is relevant and what is not. 199-209.
should be positive, but some AM For example, while we can learn a lot
technologies will still see the bed [7] “Packing in the Spheres”, David
from pharma, metal powders have
disturbed. Beyond that, the particles A. Weitz, Donev A1, Cisse I, Sachs D,
much higher densities and lower
need to be able to flow or spread Variano EA, Stillinger FH, Connelly
hygroscopy than the powders used in
well enough to get into position, and R, Torquato S, Chaikin PM. Science
this industry.
that should really be matched to 13 Feb 2004: Vol. 303, Issue 5660, pp.
Perhaps the main takeaway from
the AM technology used. Ultimately, 968-969
the panel discussions was simply
matching the requirements for the this: that everyone is interested and [8] “Real time observation of binder
process to the powder feed opens concerned with maintaining AM part jetting printing process using
the door to lower costs and more integrity, and that the interest in high-speed X-ray imaging”, Niranjan
material choices. This is complicated, understanding powder mechanisms D. Parab, John E. Barnes, Cang
but as the adage goes, “the journey and control processes is real and Zhao, Ross W. Cunningham, Kamel
of a thousand miles begins with a genuine. What that means is that Fezzaa, Anthony D. Rollett & Tao Sun,
single step.” this is a great time to be involved in Scientific Reports volume 9, Article
Additive Manufacturing. number: 2499 (2019)
Final thoughts from the [9] “Real-time monitoring of laser

powder bed fusion process using
panel discussions Authors high-speed X-ray imaging and
diffraction”, C. Zhao, K. Fezzaa, R.
A key takeaway from the panel was John E Barnes Cunningham, H. Wen, F. DeCarlo,
that powders, specifically metal The Barnes Group Advisors & L. Chen, A. Rollett & Tao Sun. June
powders, are still not well understood Carnegie Mellon University 2017 Scientific Reports 7 (1):3602
in the AM industry. From the produc- Pittsburgh, Pennsylvania, USA
tion methods, to the production cost, [10] H. R. Cunningham, A. Nicolas, J.
john@thebarnes.group
to the requirements or characteris- Madsen, E. Fodran, E. Anagnostou,
tics relevant to different processes, M.D. Sangid, A.D. Rollett, Analyzing
Filip Francqui
there is still much to learn. There is the effects of powder and post-
Granutools
a strong thirst to resolve these open processing on porosity and properties
Brussels, Belgium
queries and there is an interest in of electron beam melted Ti-6Al-4V,
filip.francqui@granutools.com
more education and information. Materials Research Letters 5 (7)
Balancing powder requirements Ryan Dehoff (2017) 516-525.
and the nature of production helps Oak Ridge National Laboratory
to understand the costs. Taking Oak Ridge, Tennessee, USA
it a step further into the process, dehoffrr@ornl.gov
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Towards a true digital twin

for the metal Additive
Manufacturing process
On July 4, 2019, Australia’s Commonwealth Scientific and Industrial Research
Organisation (CSIRO) sponsored and co-organised a one-day symposium in
Melbourne entitled ‘Towards a True Digital Twin’. The event, which followed APICAM
2019, the 2nd Asia-Pacific International Conference on Additive Manufacturing,
brought together experts in a range of relevant fields including metal Additive
Manufacturing, computational modelling, multi-scale techniques, structure-
property relations, machine learning and artificial intelligence, and digital twins of
industrial processes. Here, CSIRO Manufacturing’s Dr Dayalan Gunasegaram and Dr
Tony Murphy consider the importance of the digital twin in AM and report on some of
the event’s key findings.
For metal Additive Manufacturing How predictive modelling This assumes even greater signifi-
to reach its full potential, a cance in Additive Manufacturing, for
will transform AM
realistic virtual representation of which the ability to produce custom-
the complete process is required. ised parts contributes substantially
A ‘digital twin’ that describes the Having the ability to control and to the value proposition. This,
process in the simulated domain optimise a process is critical to however, results in products that
will accelerate process design, the successful operation of any are unique and relatively expensive.
optimisation and control, and form a manufacturing business. A reliable The slowness of the process adds
crucial part of process certification process ensures quality products that to the part cost through increased
and component qualification. It is consistently satisfy specifications. overhead per part.
expected that such technologies
will be increasingly embraced in
the connected economies of the
Value additions to the AM process
Industry 4.0 era and even become
commonplace.
Value addition to AM processes
This article draws on presenta- By predicting how a process would unfold Factors affecting bottom-line
tions and discussions from the given a set of process parameters, digital
Melbourne symposium to explore twins facilitate the following:
Increased productivity of the asset
the requirements of digital twins (machine) and labour (operator)
for metal AM processes, and Make it possible for an entirely new
part to be made right the first time it Less scrap and waste
consider the hurdles that must be
is attempted Customer satisfaction and competitive
overcome in developing them. Ideas
advantage through reduced time to market
exchanged during a road-mapping
session are also presented. While
the focus of the symposium was on Enable the building-in of quality into Potential for part certification without
an entirely new part through the use destructive testing of an expensive build
powder bed-based AM processes,
of optimal process parameters Reputation for quality assurance
most ideas that were exchanged are
applicable across a broad spectrum
of metal AM technologies. Fig. 1 How digital twins add value to a business
2 | Digital Twins for AM Processes | Dayalan Gunasegaram
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Digital twins provide

process intelligence that
informs the analysis
New in
Industry 4.0
It is the leap from digital back
to physical – in other words,
the ability to act upon data
and information that has been
analysed – that constitutes the
essence and value of Industry
4.0.
-Deloitte Insights
Fig. 2 How digital twins facilitate closed loop control, which is a cornerstone of Industry 4.0
Given this scenario, any business the need for the destructive testing of on how the process is going to
that possesses the capability to an expensive item (Fig. 1). unfold for a given set of process
produce an AM part right first time The challenge is therefore parameters. This allows changes to
has a competitive advantage through to understand how can such a be made to the inputs if it is found
reduced rejects, which has the capability be acquired. Robust that desired outcomes, such as
flow-on effects of decreased material predictive modelling capabilities that specified part quality, are not going
consumption, increased productivity realistically simulate the AM process to be achieved. The digital twins
and shortened delivery periods. and its behaviour can provide the can also assist in keeping a process
In addition, if quality can be foreknowledge that is required to plan within set boundaries, since any
assured in AM products, the the building of a new part and get deviations from the optimum path
confidence that accompanies the it right on the first attempt. That is recommended by the models can
production of each such part can lead because the models, or ‘digital twins’, be corrected through closed-loop
to the certification of this part without will be able to provide information control.
Fig. 3 A photo of a complex AM part (left) and a simulation showing the predicted residual stress (Courtesy of Vu
Nguyen)
Such control is a foundation of

Industry 4.0, which differs from the
status quo in that it espouses correc-
tive action based on an intelligent
analysis of data received from sensors
monitoring a process. The process
intelligence required for the analysis
is provided by physics-based digital
twins of the AM process. It should,
therefore, come as no surprise that,
in the metal AM industry where trial-
and-error methods are still widely
prevalent, the introduction of digital
twins in process planning and control
can cause step changes in process
productivity and part cost.
About digital twins
A digital twin is a digital model of a

real-life object, process or system.
Importantly, it is not a virtual model Fig. 4 CSIRO Data61 developed digital models of raking of the powder bed and
in isolation; it is constructed in laser melting of powders (Courtesy of Gary Delaney and Paul Cleary)
such a way as to conduct a two-way
information exchange with its physical
counterpart, informing and receiving
data, for instance from sensors that
monitor performance indicators. The development (Fig. 3). A complete, rative thought and effort are required
aim is to improve the digital twin over end-to-end capture of these various for the successful development of
time until it becomes a true reflection stages in computational sub-models linking strategies for sub-models that
of its counterpart so that the virtual is necessary for a realistic represen- retain much of the solution fidelity
model can be used in the optimisation tation of AM in the virtual domain. when crossing physics as well as
and control of the performance of its These models need to be scales.
physical twin (Fig. 2). underpinned by science so that
It is worth highlighting that digital any deviations in inputs from the
twins of processes are a relatively new experimentally validated sets can Observations from keynote
concept, although twins for products still be accommodated in predictions. lectures
(e.g. GE aircraft engines) and systems They should not only be accurate
(e.g. Tesla automobiles, the city of and fast, but they have to be tightly Recognising the significance of digital
Singapore) have existed for some integrated with one another. For twins to the metal AM industry, CSIRO
time. Even when referring to process instance, the output from the powder organised this symposium to bring
twins, most allude to logistical bed raking sub-model should be together international researchers and
process flow in factories whereas, in available as input to the laser melting managers from AM industry players,
our case, we expressly limit ourselves sub-model, although the two sub- government bodies and universities. A
to physics-based models for metal models simulate completely different total of eighty-six delegates attended
AM processes. physics and thus use entirely different from Siemens, Boeing, Thales, CSIRO,
computational methods (Fig. 4). Defence Science and Technology
Physics-based digital twins of AM This is a critical obstacle since (DST), Australia’s Nuclear Science
processes there are usually incompatibility and Technology Organisation (ANSTO),
The metal AM process comprises issues between the mathematical Lawrence Livermore National
several stages involving complex approaches. This is exacerbated by Laboratories (LLNL), RMIT University,
physical and metallurgical the fact that the sub-models often University of Melbourne, Swinburne
phenomena. For instance, in powder treat phenomena occurring at vastly University, Flinders University,
bed systems, these include powder different time and length scales, from Pennsylvania State University,
bed raking, heat transfer and flow microstructures (nanometres) to Nanjing University of Aeronautics and
in the molten pool, microstructure powder (micrometres) to part (up to Astronautics and University of Texas
formation and residual stress metres). Thus, considerable collabo- at Arlington, to name just a few. The
event was sponsored by software LLNL is presently studying the use extrapolated that to the AM process,
vendors for ThingWorx, Solvia, of machine learning (ML) to predict where the number of permutations
Simufact, Materialise and Flow-3D, process fidelity (via track width) and combinations in terms of process
emphasising the interest from the based on in-situ high-speed video parameters easily surpasses that
commercial software community. monitoring, but these methods will of welding, and which is slower and
The specific aims of the sympo- be later augmented by sophisticated more expensive, it would take much
sium were to define the requirements algorithms that can accelerate part longer to reach that level of knowl-
for a true digital twin of AM, identify certification. edge – unless it is done differently.
the main barriers to developing such Difficulties in optimising
software models, discuss potential Fundamental physics relating microstructures, part properties,
solutions to overcome those barriers to powder-bed technology and and control of distortion after a
and plan a roadmap that can provide complexity in materials build were listed as key challenges
general guidance for the development The main discussion points from the that can be tackled using digital
of digital twins. These aims were presentation by Prof Leila Ladani, twins. The speaker mentioned that
achieved through a combination of University of Texas at Arlington, USA, other benefits of using digital twins
keynote lectures, poster presenta- focused on the fundamental physics included:
tions and facilitated discussion relating to powder bed technology and • A shortened time for bringing a
sessions. Keynotes were spread complexity in materials. The essential product to market
between modelling, experimental take-aways from this presentation
• Increased chances for introducing
validation and machine learning/arti- were as follows:
process and product design
ficial intelligence for model speed-up
• The physics associated with the innovations in the industry
purposes.
various phenomena and materials • Improved agility to successfully
Some of the main messages from
are too complex to be modelled follow market trends and the
the symposium’s keynote speakers
in a computationally efficient way, creation of a process-savvy
are outlined below. These were the
hence it is advisable to identify workforce.
opinions of the speakers, and some
a few parameters that have the
may not necessarily be incorporated Some of the sub-models that
most influence and concentrate
in the creation of the roadmap. can become the building blocks of a
on modelling those influences
digital twin for metal AM processes
using suitable simplifications and
The use of digital twins in tailoring were considered, and some hurdles
assumptions, at least for a start
metal AM processes in their development were outlined.
(for instance, consider modelling
The overarching theme of the These include the lack of a coordi-
the powder bed as a block rather
presentation by Dr Ibo Matthews, nated global approach between the
than as a collection of particles
Lawrence Livermore National Labora- stakeholders who are driven by their
using ‘effective powder thermal
tory (LLNL), USA, was the potential own agendas, the unwillingness of
conductivity’)
that exists for the use of digital twins large multinational corporations to
in tailoring metal AM processes. A • It is critical to have accurate
share knowledge and the difficulty in
sound understanding of the physics thermophysical properties, which
synthesising the huge amount of data
involved, as well as the availability of may be temperature- and/or laser
being generated in the field.
suitable experimental data for valida- wavelength-dependent
tion purposes, were emphasised as • The research community needs Enabling weight reductions in parts
prerequisites for accurate modelling. more innovative approaches to be The main thrust of the presentation by
The following phenomena were able to model the processes with Prof Dongdong Gu, Nanjing University
among those listed as needing further the lowest computational costs. of Aeronautics and Astronautics,
in-depth understanding: China, was to bring to the attention
Modelling should go hand-in-glove of the delegates the importance of
• Liquid spatter due to unstable
with experimental efforts the metal AM industry to aeronautics
local laser/melt-pool/powder bed
In the presentation by Prof Tarasankar and space in terms of enabling weight
interactions
DebRoy, Pennsylvania State Univer- reductions in parts (through the
• Depressions in the powder bed sity, USA, compelling justification design freedom it affords) and the
due to vapour pressure and was provided for using modelling acute need to develop more suitable
pore formation as a result of the hand-in-glove with experimental materials and novel process innova-
highly dynamic interactions and efforts for expanding the knowledge tions to achieve this purpose.
the resulting flow profiles and base associated with metal AM Again, the requirement for an
subsequent solidification processes. DebRoy mentioned that in-depth understanding of the science
• The effect of all of the above and it took the welding community close underlying various processes was
cooling rates on microstructure to a century to develop the knowhow emphasised, with particular refer-
evolution. that they currently possess. If we ences to particle flow, laser energy
Digital Twin Digital Twin Digital Twin

Product Production Performance
Insights from performance
Virtual product Virtual Production Real Production Real Product
Continuous improvement
Fig. 5 Linkages between digital twins of a product, its production and its performance (Courtesy Siemens)
absorption, powder melting thermo- statistical procedure that deals with Discussion on roadmap
dynamics and surface morphology potentially correlated variables). One
development
evolution. of the most sought-after outputs
from machine learning is the
In the second half of the symposium,
Training machine learning models ranking of features (structure) by
delegates took part in a collaborative
Dr Amanda Barnard, CSIRO Data61, how influential they are in predicting
workshop overseen by professional
Australia, considered the intricacies (controlling) labels (properties).
facilitators from ThinkPlace, a
of training machine learning models It was suggested that one must
design and systems transforma-
based on experimental results and pay as much attention as possible
tion consultancy. The aim was to
solutions from validated physics- to the available data, ‘clean’ the
collectively explore the vision, benefits
based models. These ‘surrogate’ data and standardise, as well as
and features of digital twins, the
machine learning models typically attempt to extract as many features
hurdles faced and their solutions
provide solutions faster than compu- (relationships) as possible from it.
within six domain topics suggested
tationally prohibitive physics-based Models should be cross-validated
by CSIRO. Additionally, the priority
models, and so are prime candidates and optimised to ensure that they
of solutions for achieving the vision
for use in real-time closed-loop make sense in relation to domain
and the critical path to achieve these
control as artificial intelligence knowledge.
solutions – the roadmap forward –
for data analysis in an Industry 4.0
was considered. The outcomes of the
setting. The industrial applications of digital
workshop are summarised below.
Barnard mentioned the require- twins
ments for selecting an appropriate, Chris Vains, Siemens, Australia,
Vision
interpretable machine learning focused on examples from industry
The participants concluded that a
model and highlighted the need for sectors that have already embraced
digital twin for the metal AM industry
combining simulations (predictions) digital twins in non-AM applications.
should ideally:
with informatics (inference). She This helped delegates imagine how
cautioned against the likely traps of they might expect the metal AM • Accurately predict the process
biases in data and learning as well as industry to react to the application of and include a multi-disciplinary
data recording errors, emphasising a well-performing digital twin in their approach
that surrogate models can inherit own realm. The speaker emphasised • Comprise multi-scale models
(and often amplify) the influences the need to create a ‘holistic’ digital that are robust
from these. twin that encompasses product
• Be validated and reliable
Possible challenges to creating (design), process (production) and
machine learning models were performance in order to facilitate • Be accessible to everyone
identified as: insufficient data sets, continuous improvements in the • Have links to an open-access
missing data, outliers and difficulties delivery of solutions to customers database that is updated by
with feature label extraction (a (Fig. 5). scientists globally
Domain Hurdles identified Potential solutions proposed

1 AI and speed of • Access to data • Training and skilled personnel in
computing for timely • Technology limitations various domains
solutions • Open data access to create more
specific, simple and informed
models
• Increased computational power
through global AI and neural
networks
2 Experimental data for • Quality of data and lack of protocols • International collaboration on data
model validation for experimentation management, framework and
• Unwillingness to share data and standards
results with different groups • Incentives for increased
collaboration, sharing of data and
experiments (e.g. Git Award)
• Creation of protocols for data
experiments
3 Shortcomings in • Gaps in models needing domain • Research and development for

existing computational expertise to fill and address better technology at lower costs
approaches • Technology limitations in multi- • A connected network to share
scale processing, time and 4D visual computational needs
results
• Lack of validation standards and
test cases
4 Lack of material • Lack of data in materials and • Creation of an open database of

property data properties relevant to AM AM materials with funding for
• Lack of consistent formatting international public research
standards • Development of standards for
• Lack of commercial interest in methods, materials and data
sharing data informatics for AM
5 Difficulties in linking • Lack of standards for data and • Provide verification and validation
codes (different scales metadata which propagates measures and standards
and physics) uncertainties, with missing links • Use open source software or
and parameter information current software to its full potential
• Bridging multi-disciplinary teams
and experts
• IP and legal issues
6 Industry and research • Lack of trust and shared vision • Embedding researchers within
partnership • Misalignment between researchers industry and vice versa to build
(publication-driven) and industry understanding on both sides
(dollar-driven) on successful • Communication and upskilling to
outcomes, expectations and reduce mismatches on perspectives
acceptance of failures • Consider rewards for common goals
Table 1 Hurdles and solutions in the implementations of digital twins for AM, as based on the roadmap discussions
• Be able to accommodate a range

of materials
• Be able to assist in product
design by providing feedback to
designers
• Be able to assist in virtual testing
by predicting localised part
properties
• Be able to assist with closed-
loop-control of AM machines
Benefits
The participants saw the potential
benefits of digital twins as:
• Enabling the virtual testing and

use of new materials sooner Fig. 6 A section of the delegates during the discussion session for roadmap
• Enabling the development of new development
materials for AM
• Enabling the extension of AM
products into new applications 3. Shortcomings in existing a reasonable period. An example of
(e.g. by improving properties computational approaches a more specific requirement is to
through a deeper understanding 4. Lack of material property data support the development of novel AM
of influencing factors) alloys and associated processes to
5. Difficulties in linking codes
satisfy strong demand for lightweight
• Allowing the testing of ‘crazy’ (different scales and physics)
and heat-resistant AM structures
ideas in the virtual world,
6. Industry and research partnership from sectors such as aerospace.
sparking innovation
The participants agreed that a
• Allowing a deeper awareness of In three round-robin sessions, the
digital twin would significantly help
production costs participants moved between domains
the AM industry, especially as it tran-
they themselves selected in order
sitions into the connected economies
Features to explore the hurdles and potential
of Industry 4.0, where the focus will
The participants listed the required solutions in those domains. Ideas
be on productivity improvements in
features of digital twins as: were recorded onto poster templates,
the production process. In a future
which were subsequently used for the
• Able to predict defects in products publication, prioritised solutions, as
prioritisation of potential solutions.
or faults in processes well as a suggested roadmap, will be
The ideas that were put forward
dealt with in some depth.
• Capable of arriving at an are summarised in Table 1. Priority
optimised process Solutions and Roadmap are being
• Able to provide data for surrogate developed and will be reported on Authors
ML models shortly in a separate publication.
• Able to deliver solutions for Dr Dayalan Gunasegaram
real-time decision-making Principal Research Engineer/Scientist
Final remarks
• User-friendly so that they can Dayalan.Gunasegaram@csiro.au
be used by anybody in the
This one-day symposium brought Dr Tony Murphy
product design and production
together international stakeholders Chief Research Scientist
environments
in the metal AM industry to deliberate tony.murphy@csiro.au
on the creation of a true digital twin
Hurdles and solutions
for AM processes and to exchange CSIRO Manufacturing
The participants discussed the
ideas towards creating a roadmap. Private Bag 10
hurdles and solutions for the six
It was abundantly clear from these Clayton South VIC 3169
pre-selected domains as:
discussions that the metal AM Australia
1. AI and speed of computing for industry needs computational www.csiro.au
timely solutions assistance for several reasons. An
2. Experimental data for model overarching requirement is to expand
validation the scientific knowledge base within
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