Page 32 - 3D Metal Printing Summer 2016

3D
Add and Subtract All in One
Modular 3D-Printing System
Designed for Addition to Machine Tools
The Lens Print Engine provides Optomec, Albuquerque, NM, with metal 3D-printing technology in a modular form for rapid integration with other metalworking platforms such as CNC mills, lathes, robots, custom gantries, or even laser cutting and welding systems, according to company officials. Lens Print Engine components include Optomec’s proprietary SteadyFlow powder feeders, a Lens processing head with interchangeable nozzles, fiber laser, integrated tool-path-generation soft- ware, SmartAM closed-loop controls and full safety packages. The engine, according to Optomec, is targeted for customers wishing to upgrade their existing metalworking systems with AM capabilities or for machine-tool OEMs as a value-add option to their current system offerings.
The SmartAM process control monitors and adjusts key process param- eters during part build to help ensure consistency in metal parts. As the parts are built layer upon layer, heat from the laser builds up in the part, which can affect the size of the melt pool and, in turn, can affect the microstructural properties and dimensional accuracy of the printed metal. The control adjusts to compensate for the buildup.
SmartAM technology consists of special focusing optics and a melt- pool sensor, housed within the Lens’ deposition head. The sensor monitors the build process and control software automatically adjusts laser power to keep a constant melt-pool area. Numerous studies have demonstrated that this closed-loop method is effective in controlling heat input and cooling rate, and thus promotes microstructural uniformity that defines the mechanical properties of the printed metal, according to Optomec officials. They note that maintaining melt-pool size also ensures geometric and dimensional integrity of the final part. In operation, the control reportedly reduces laser power dramatically from the first layer to the end of the build.
Optomec: www.optomec.com
Rapid Manufacturing via AM and SM
The Cybaman Replicator, from Cybaman Technologies, Chesire, UK, is a fully auto- matic computer-controlled rapid-manufacturing system employing both subtractive or additive processes to produce components. Developed specifically for high-speed machining of 3D metal components to 170 cu. mm, the machine presents each facet of a workpiece to a cutting tool in an automatic sequence. Tool paths are generated using hyperMill CAD/CAM software and then converted into machine movement with the Cybaman postprocessor.
The workstation houses a six-axis, PC-based, CNC-software-driven positioning system comprising a three-axis articulated robotic manipulator and high-speed machin- ing spindle mounted on three linear axes. The compact machine, with remote monitoring and control, can be supplied with a laser powder-deposition head for rapidly building metal parts directly from a CAD model.
It can work with various materials including aluminum, titanium, zirconium oxide, cobalt chrome, ceramics, precious metals and acrylics such as Plexiglas.
Cybaman Technologies: www.cybamantech.co.uk
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30 | 3D METAL PRINTING • SUMMER 2016
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