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█ Powder-based laser fusing with metals (LaserCUSING)
Information about formnext powered by TCT
“AM Factory of Tomorrow” opens up a
great deal of potential with modular
machine configurations
From vision to reality: New machine and plant
architecture with the seal “Industry 4.0”
Lichtenfels (Germany), November 19th, 2015: At formnext powered by TCT in
Frankfurt, Concept Laser presented a new machine and plant architecture. This is
a real first which shows that the vision has already become firmly integrated in
the company’s strategy. The new, integrated machine concept under the heading
of “AM Factory of Tomorrow” promises a new level of Additive Manufacturing in
terms of quality, flexibility and increase in performance. The modular integration
of the machine technology into the manufacturing environment is amazing thanks
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to a radically new approach in the design of process components. Ultimately, this
makes faster and more economic industrial production solutions available. This
vision will soon be reality: Concept Laser has announced a market launch by as
early as the end of 2016.
The previous solutions for machine and plant technology in the market all relied on
ideas such as “more laser sources,” “more laser power,” “faster build rates” or
“expansion of the build envelope sizes.” The machine technology represented a
“standalone” solution without any consistent integration into the manufacturing
environment. Build job preparation and build job process proceeded sequentially.
Concept Laser is now attempting, with a new machine architecture, to expand the
usually quantitative sections with new, qualitative aspects. “In essence,” says Dr. Florian
Bechmann, Head of R&D at Concept Laser, “it is about splitting up build job
preparation/build job follow-up processing and Additive Manufacturing in any number of
combinable modules. With comparatively large build envelopes, build jobs can be
carried out with a time delay. The intention is that this should drastically reduce the
“downtimes” of previous stand-alone machines. There is plenty of potential here for
improving the level of added value in the production chain. In contrast to purely
quantitative approaches of previous machine concepts, we see here a fundamentally
new approach for advancing industrial series production one step further.”
The new concept of an “AM Factory of Tomorrow”
At present, regional printing centers are being created as service providers all around
the globe. This development is characterized by the transition from “prototyping” to a
desire for flexible series production at an industrial level. The AM users experience the
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pressure of traditional manufacturing: demand for space, expansion of the machinery,
increasing operating tasks and in particular times. In the new concept from Concept
Laser, interesting solutions are offered in this regard: Production is “decoupled in
machine terms” from the preparation processes. The time window for AM production is
increased to a “24/7 level,” meaning that there is higher availability of all components.
An automated flow of materials palpably reduces the workload for the operators.
Interfaces integrate the laser melting machine into traditional CNC machine technology,
as is important for hybrid parts, for example, but also into downstream processes (postprocessing / finishing).
Decoupling of “pre-production,” “production” and “post-processing”
The new plant architecture is characterized essentially by decoupling of “preproduction,” “production” and “post-processing.”
This includes among other things
flexible machine loading and physical separation of the setting-up and disarming
processes. The objective here was to coordinate the process components in a more
targeted way with interfaces and increase the flexibility of the process design to create
an integrated approach. This becomes possible thanks to a consistent modular structure
of “handling stations” and “build and process units” which, in terms of combination and
interlinking, promises considerably greater flexibility and availabilities. It will also be
possible to handle the present diversity of materials better, and ultimately more
economically, through a targeted combination of these modules. For example, in future
the machine user will be able to use the modules to very precisely “customize” the
production assignment in terms of the part geometry or material. All in all, the level of
efficiency and availability of the production system will be markedly increased, along
with a significant reduction in the amount of space required. Simulated production
scenarios have in fact shown that this space can be reduced by up to 85% compared to
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the possibilities that exist at present. In addition, the laser power per m 2 is increased
seven-fold. Dr. Florian Bechmann says: “The build rates have increased enormously
thanks to the multilaser technology. The build envelope sizes have also experienced
considerable growth. We now want to use an integrated machine concept to highlight
the possible ways that the approaches of “Industry 4.0” can change Additive
Manufacturing as the manufacturing strategy of the future. There is plenty of potential
here to increase industrial added value and enhance suitability for series production.”
Solutions from the factory building kit – the modular process station
The process station shown has a build envelope of 400 x 400 x >400 mm3, laser
sources, process gas management and filter technology are integrated in the module,
and the layer thicknesses are within the usual range. In addition, the machine solution
has a variable focus diameter and will be available optionally with 1, 2 or 4 laser optics
with a laser power ranging from 400-1,000 W. An available redundancy of the lasers will
ensure that, if one laser fails, the remaining three lasers will still cover the entire build
plate – the build job can still be completed. Dr. Florian Bechmann says: “More and more
laser sources only increase the expected speeds to a limited extent. But ultimately they
also increase the level of complexity and dependencies, which can result in vulnerability,
and thus turn the desired positive effect into a negative.”
Solutions from the factory building kit – the modular handling station
The new handling station has an integrated sieving station and powder management.
There is now no longer any need for containers to be used for transportation between
the machine and sieving station. Unpacking, preparations for the next build job and
sieving therefore take place in a self-contained system without the operator coming into
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contact with the powder. But what also makes a modular handling station attractive is
the specific configurations: A handling station can be linked to two process stations to
create a “manufacturing cell.” The factory building kit also enables several handling
stations to be joined together to create a material preparation facility and be physically
separated from the process stations.
Combinations of modules from the factory building kit
The new factory building kit boasts three types of modules: process module, dose
module and “overflow” module, which are to be offered in different heights. What is
remarkable is the direct link between these modules without the use of any pipes or
tubes and their identification via RFID interfaces. Accordingly, the result is a reliable flow
of materials with high material throughputs along with great flexibility when there is a
need to supply different types of materials for the build process and handle them. “In the
future,” says Dr. Florian Bechmann, “we think that AM factories will be largely
automated. The transport of material or entire modules can be envisaged as being done
by driverless transport systems. This could then be the next step in the development.
Additive Manufacturing can be automated to the maximum extent.”
New type of 2-axis coating process
The new machine concept has a new type of 2-axis coating system which enables the
return of the coater to be performed in parallel with exposure. This results in a
considerable time saving during the coating process.
The coater blades, optionally made of rubber, steel or carbon, can be changed
automatically during the build job. This results in several advantages according to Dr.
Florian Bechmann: “An automated tool changing system, as is the case with CNC
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machine technology, promises a high level of flexibility, time advantages when setting
up the machine, and reduces the level of manual intervention by the operator. We
deliberately talk here about ‘robust production’.”
Print approved – ask for copy
Info block on 15 years of Concept Laser
In 2001, one year after Concept Laser GmbH was founded as a start-up by Frank
Herzog, the company unveiled the world’s first industrial laser melting machine. Today
the pioneer’s LaserCUSING process has provided him with more than 50 granted
patents and 100 patent applications. 3D metal components are produced with enhanced
features in a digital process chain which it would not be possible to manufacture using
traditional machining methods. With more than 550 machines installed, Concept Laser
is one of the key drivers of powder-based laser melting with metals. The process is also
referred to as a “green technology” due to the way that resources are conserved. For
example, today the aerospace industry, the automotive industry, medical technology
and other sectors focus strategically on 3D metal printing as the manufacturing strategy
of the future and an embodiment of “Industry 4.0.”
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Captions █████████████████████████████████████████████
Caption 0: “AM Factory of Tomorrow”: Smart and “robust” production with AM modules
from Concept Laser at an industrial level with a minimal footprint.
Caption 1: Dr. Florian Bechmann, Head of R&D at Concept Laser: “More and more laser
sources only increase the expected speeds to a limited extent. But ultimately they also
increase the level of complexity and dependencies, which can result in vulnerability, and
thus turn the desired positive effect into a negative.”
Caption 2: Basic idea behind the new machine architecture from Concept Laser:
Decoupling the handling unit and process unit
Caption 3: Option for combining a handling station with two process stations
Caption 4: Handling modules may form a central metal powder preparation station
Caption 5: Linking together the “AM Factory of Tomorrow”: The AM Factory of
Tomorrow is set to be a flexibly expandable, high-grade automated and centrally
controllable metal production system which is focused fully on the production
assignments in hand
All photo credits: Concept Laser GmbH, Lichtenfels (Germany)
Contacts ███████████████████████████████████████
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Concept Laser GmbH
An der Zeil 8
D-96215 Lichtenfels
Germany
Phone: +49 (0) 9571-1679-0
Internet:
www.concept-laser.de
Press contact:
Daniel Hund
Phone:
+49 (0) 9571 / 1679-251
E-mail:
d.hund@concept-laser.de
Concept Laser at a glance ██████████████████████████
Concept Laser GmbH is an independent company based in Lichtenfels, Germany. Since its
founding in 2000, it has been a leading innovator in the field of laser melting technology with the
patented LaserCUSING® across many industries.
The term LaserCUSING®, a combination of the C from CONCEPT Laser and the word FUSING
(to fully melt) describes the technology: The fusing process uses 3D CAD data to generate
components layer by layer.
This process allows the production of complex component geometries without tools in order to
implement geometries as components that are difficult or even impossible to achieve with
conventional manufacturing methods.
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With the LaserCUSING® process, conformal cooling can be used to create tool inserts as well
as direct components for the jewelry, medical, dental, automotive and aerospace industries. This
applies to prototypes and series parts.
The company offers both standard systems and custom concepts for metal laser melting. At
Concept Laser, full-service as an option means that customers can either purchase their own
metal laser melting systems or rely directly on services, including development services.
Laser machining systems from Concept Laser process powder materials made from stainless
steel, hot work tool steels, cobalt-chromium alloy, nickel-base alloy as well as reactive powder
materials such as aluminum and titanium alloys. Precious metals such as gold or silver alloys for
jewelry making are also an option.
LaserCUSING® offers new perspectives in terms of cost and speed for efficient product
development in industries such as:
•
Jewelry
•
Medical and dental technology
•
Aeronautics and space industry
•
Tool and mold construction
•
Automotive and motor sports
•
Mechanical engineering
The systems reduce development time and costs substantially while offering much greater
flexibility in product development.
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The high quality standards, level of experience and successful track record of Concept Laser
guarantee reliable and cost-effective solutions with proven performance in everyday production,
with a particular focus on unit cost reductions.
The art of LaserCUSING® by Concept Laser
Ideas for laser melting with metals in the following areas of application: automotive and
motorsport, aerospace, medical and dental technology, die and mold making as well as
the wider engineering business.
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