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█ Laser melting with metals (LaserCUSING)
Information on Euromold 2014
Multilaser
process
technology,
monitoring
improved
and
3D
segmented
exposure strategy for the laser melting
of metals
Concept Laser presents the new M2 cusing
system featuring numerous innovations and a
modern machine design
Fresh ideas for 2015 from the pioneer of laser melting
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Lichtenfels (Germany), December 2nd, 2014: Concept Laser raised the stakes in
terms of innovation at Euromold 2014. The centerpiece of the innovations was
without doubt the multilaser technology. Concept Laser is comprehensively
upgrading its models in order to improve performance.
In addition, the new M2 cusing features modern machine design and numerous
innovations, was presented as a fully integrated laser melting system. Concept Laser
has in particular improved the process: here the focus was on innovations in the
segmented exposure strategy and on a ground-breaking quality assurance module
QMmeltpool 3D. Apart from this, two new certified materials were also presented in
Frankfurt. These new approaches are the launchpad for Concept Laser's 15th
anniversary.
Presentation of the new M2 cusing
The new M2 cusing is being brought out with a new, modern appearance. However, in
addition to its new look, the machine also has a fully integrated structure, i.e. there are
no longer any external components for the laser and filter system. This self-contained
solution provides benefits for the user in terms of the accessibility of the system
components as well as greatly reduced space requirements. However, it is not just
externally that the new machine design underlines the enhancement of the system
technology. The new M2 cusing is, for instance, equipped with a new filter design. This
has increased the surface area of the filter by a factor of five – from 4 to 20 square
meters. The new filter module has been designed with fixed tubing as well as being fully
integrated into the system. The frequency with which the filter has to be replaced can be
reduced to such an extent that the overall throughput of the system is increased. This
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enhancement is important when using the multilaser technology. With the increased
formation
of
smoke
particles,
the
new
filter
further
enhances
productivity.
"Significantly faster build rates demand safer filter replacement concepts. Every filter
change must be quick and easy. We have incorporated the new enhanced filter
technology with safety as our primary consideration", explains Dr. Florian Bechmann.
For instance, the M2 cusing is fitted as standard with a water-submersible filter in order
to guarantee safety when changing the filter.
Series enhancement with multilaser technology
"Our product range is now enhanced with multilaser technology and it directly affects the
exposure time. Our experience has shown that build rates can be increased by up to
80%. That's a very pleasing result", notes Dr. Florian Bechmann, Head of Development
at Concept Laser. The multilaser technology is initially being incorporated into the
medium size segment. For instance, a multilaser version of the new M2 cusing – called
the M2 cusing Multilaser – is available right now. It's available with 2 x 200 watt lasers,
or alternatively with 2 x 400 watt lasers. What's more, Concept Laser has also signalled
the arrival of multilaser technology in their largest machine, the X line 1000R. In addition
to the X line 1000R which is already well established in the market, in the near future the
X line 2000R will also be available, and will be fitted with 2 x 1000 watt lasers. The aim
is to drive ever faster construction speeds which are required by users in the aerospace
and automotive industries.
Segmented exposure strategy improves the performance characteristics of
components.
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Concept Laser has likewise raised its game in relation to its exposure strategy. The key
term is segmented exposure. It is common that higher laser power produces a rougher
surface finish. "Our new systems technology implements the hull-core principle, which
enables density and surface quality to be controlled independently”, says Dr. Florian
Bechmann. This means that segmented exposure has an influence on the outer parts of
the component – including overhangs and high-density areas of components – in a
targeted manner. "An optimised exposure strategy improves both the level of quality and
build speeds." The end result is that a component's performance characteristics can be
significantly improved through the use of segmented exposure strategy.
Enhanced real-time monitoring of the construction process with the QMmeltpool
3D
Concept Laser has demonstrated key enhancements in real-time process monitoring for
quality assurance purposes. "Inline process monitoring" is one of Concept Laser's
strategic technology fields, and one which we are now expanding with the QMmeltpool
3D", says Dr. Florian Bechmann: "If we can dynamically micro-analyse the construction
process, the level of quality increases. Important key industries with their sophisticated
applications have enabled us to develop this important innovative step", Dr. Bechmann
continues. In a comparable manner to computed tomography (CT), the new QMmeltpool
3D makes it possible to generate 3D data sets that corelate directly to the component
and/or it´s structure. According to Concept Laser, this allows local effects that arise
during the construction of the component to be clearly identified and analysed. The
practical added value of this innovation is not just that it is an original way of providing
real time quality assurance, but also that production builds can be optimised through
iterative variation of the parameters. Support structures can be adapted, and above all,
the construction of the component can be structured in a more efficient and production-
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friendly manner. And not least, real time monitoring opens new opportunities in the
materials research field.
A world first: New materials for laser melting systems
Concept Laser's development center has certified two new materials, both of which
premiered in Frankfurt. For high-temperature applications, Inconel 625 is now available.
This material is mainly intended for use in turbine construction where components are
exposed to high thermal stress of up to 1000°C. The second material is the stainless
steel, 17-4 PH. This material can be hardened and consequently made highly resistant
to abrasion, wear and corrosion. These properties are attractive above all in relation to
medical instruments. The certification of 17-4 PH stainless steel applies to the Mlab
cusing R, M1cusing, and the M2 cusing series.
Reprint permitted - copy requested
Captions
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Caption 1: Dr. Florian Bechmann, Head of Development at Concept Laser " QMmeltpool 3D
makes it possible to produce a 3D image of the component down to the scale of local effects.
Process parameters can be adjusted and designs can be made more production-friendly."
Caption 2: 3D representation of QMmeltpool 3D
Caption 3: The design of the new M2 cusing: fully integrated systems technology featuring
numerous innovations
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Caption 4: Medical instrument made of 17-4 PH stainless steel: abrasion- and corrosionresistant
Caption 5: Practically useful: multilaser technology
Caption 6: Segmented exposure according to the shell-core principle for optimum density and
surface quality
All image sources: Concept Laser GmbH, Lichtenfels
Concept Laser at Euromold 2014
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Booth number: Hall 11.0 Booth D66
November 25 - 28, 2014
Contact ████████████████████████████████████████████████████
Concept Laser GmbH
An der Zeil 8
D-96215 Lichtenfels
Germany
Phone: +49 (0) 9571 1679 - 0
Internet:
www.concept-laser.de
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Press contact:
Daniel Hund
Phone:
+49 (0) 9571 1679-251
E-mail:
d.hund@concept-laser.de
About LaserCUSING®
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Keyword: LaserCUSING®
The LaserCUSING® process is used to create mechanically and thermally stable metallic
components with high precision. Depending on the application, it can be used with stainless and
tool steels, aluminum and titanium alloys, nickel-based superalloys, cobalt-chromium alloys or
precious metals such as gold or silver alloys.
Procedures
With LaserCUSING®, finely pulverized metal is fused using a high-energy fiber laser. After
cooling, the material solidifies. Component contour is achieved by directing the laser beam with
a mirror deflection unit (scanner). Construction takes place layer by layer (with each layer
measuring 15-100 microns) by lowering the bottom surface of the construction space, then
applying and fusing more powder.
Concept Laser systems stand out due to their stochastic control of the slice segments (also
referred to as "islands"), which are processed successively. The patented process significantly
reduces tension during the manufacture of very large components.
Concept Laser Overview
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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 with the patented
LaserCUSING® technology across many industries.
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The term LaserCUSING®, a combination of the C from CONCEPT Laser and the word FUSING
(to fully melt), describes the technology: the fusing process generates components layer by
layer using 3D CAD data.
The method allows the production of complex component geometries without tools to create
parts that are difficult or even impossible to achieve through conventional manufacturing.
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. With
Concept Laser, full-service as an option means that customers can either purchase their own
metal laser melting systems or rely directly on service and 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 racing
•
Mechanical engineering
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The systems reduce development time and costs substantially while offering much greater
flexibility in product development.
The high quality standards, level of experience and successful track record of Concept Laser
guarantee reliable and cost-effective solutions with proven performance in daily production, with
a particular focus on unit cost reductions.
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