Metal Addictive Manufacturing of Medical Device
In many areas doctors and patients are reliant upon custom-made designs or individualized small series for the production of medical devices. Both the materials and workmanship of the devices have to meet high quality standards. Products must also be quickly available, and preferably at an economical price. The metal additive manufacturing method can be used to manufacture almost all complex forms of medical devices, which were almost impossible with conventional methods, quickly, cost-effectively and with high quality. The AM simplify the manufacturing process of tooth caps, crowns and further dental components.
Removable Partial Denture (RPD) Framework
Removable Partial Denture (RPD) Framework The part is a metal framework for a removable partial denture (RPD) by SLM additive method. When fully assembled, the RPD is a denture for a partially edentulous dental patient. The conventional manufacturing of cast frameworks involves a lot of work and time. But AM is faster and has a high volume output, more accurate and parts have high strength.
Developed and manufactured of a customized and precision-fit implant with high permeability for liquids and perfect heat dissipation. For the actual production they used an SLM additive method. The porosity of the implant is 95%, so liquids can flow through with the least possible resistance and the bone tissue optimally coalesces with the outer edges. Even the construction time was just a matter of hours.
Developed and manufactured unique Trabecular Structures using the EBM (electron beam melting) additive method. The EBM process offers new possibilities to optimize the porous coating design of the trabecular structure. EBM Trabecular Structures are optimized for improved primary fit and osseointegration.
Metal Addictive Manufacturing of Aeronautics
Manufacture of lightweight components using tool-free AM process reduces fuel consumption, material costs and CO2 emissions. Engine and turbine parts as well as cabin interior components are typical applications area for AM in aerospace industry. This is where the benefits of innovative AM technology come to the fore: Parts having complex geometries and defined aerodynamic properties can be manufactured quickly and cost-effectively. The AM technologies is suitable for small production runs. This is why aerospace companies use AM for their future production strategies.
Robust titanium bracket
The use of titanium as the material for the retaining brackets of our satellites has proven highly effective.
The main weakness, however, was the connection of the brackets with the carbon panel of feed and reflector assembly because here the thermal stress was negative factor.
Thanks to Additive Manufacturing, we were able to redesign the bracket and eliminate this vulnerability.
There were other benefits, too, such as shorter, more cost-effective and more lightweight production.
The Aerospace industry is a huge and diverse market with additive manufacturing applications found in basically all segments,
such as commercial and military aircraft, space applications, missiles and various subsystems like engines and accessories.
Due to the importance of weight optimization it is not uncommon with Buy-to-Fly ratio as high as 15-20 for flying components,
resulting in a lot of costs and a high environmental footprint.
Additive manufacturing can produce lightweight components with a Buy-to-Fly ratio very close to 1.
Direct metal printing (DMP) is suitable for establishing an injector thermal design that prevents heat from soaking back to the sensitive propellant valves seat and the spacecraft itself.
The absence of tooling access constraints allows the redesign of the thermal standoff by controlling the conductivity using a metal scaffold instead.
Injector parts made from a flight-capable titanium (Ti6Al4V) are close to the product warranty requirements of aerospace and the design requirements of rocket motor designers.
Metal Addictive Manufacturing of General Industry
Sustainable energy efficiency, constant cost pressures, special purpose parts in short-run productions, unrelenting deadline pressures – industrial companies are confronted with many challenges. The production of small runs may be less cost-effective with traditional tool-based method. Moreover, it takes a lot of work and costs to quickly respond to changed parts geometry before production begins. AM provides industrial companies with a new solution for tool-less production, while allowing maximum freedom of design. AM is ideally suited for rapid prototyping. Providing material only where it is needed for mechanical strength or functionality, this solution can also manufacture lightweight parts with highly complex geometries
Oil filter housing
Tool-less AM is a cost-effective solution, especially for the continuous production of small quantities. The design changes of the part geometries can be made at any time before production. One other advantage is the practically unlimited availability of spare parts, which can be manufactured as and when they are needed. The oil filter housing is made of AlSi10Mg material and is use d as an automobile oil filter.
Heat-exchanger application exemplifies the importance of DMP (direct metal printing) in the lean manufacturing space for creating low-volume, high-complexity metal components. With DMP technology, no assembly is required since the part is produced in on continuous operation, no matter how complex the parts or how delicate the features. These parts are now performing critical functions under challenging conditions such as continuous stress, high pressure, repeated use and extreme temperatures.
Motor Cylinder Head
The new design of the cylinder head, speciﬁcally aimed at the AM process, begins by reducing functional elements of the component to the essentials. The next step is to define the suitable surface and volume structure and then integrated it into the component. The value of an AM parts can only be optimized if the component is specific to the AM process. Ideally, material is only generated in those areas where functionality requires it. AM improves the motor efficiency and thus increases the performance of the entire system.