Aerospace – Dev

Discover the Latest Advancements in Material Quality Control for Additive Manufacturing

Ashkhen — Wed, 21 Aug 2024 14:06:51 +0000

An exclusive one-day workshop, hosted by Verder Scientific, focused on additive manufacturing, at the innovative Solvus Global facilities.

Additive Plus, as a partner of Verder Scientific, will join this event.

When

September 18th, 2024

Time

8:00 AM – 7:30 PM (EST)

Where

Solvus Global
272 Nashua Street
Leominster, MA 01453

Cost

$75.00

The deadline for entries is Friday, September 13th, 2024.
The full agenda will be released by August 30th, 2024.

Presentations from Leaders in Research & Industry

– Additive Manufacturing is Multiplicative Manufacturing: Opportunities at the nexus of traditional and novel technologies

-Powder characterization of Feedstock for Additive Manufacturing

-Certification & Challenges of Additively Manufactured Components

-Industrialization of Additive Manufacturing

-And more!

These topics will be enriched by a hands-on training using the latest quality control equipment. We will also have a networking event with top additive manufacturing professionals.

To register and payment, please use this link.

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Farsoon SRS (Support Free) Technology: reduce support up to 99.8%

Ashkhen — Thu, 01 Aug 2024 09:34:50 +0000

Farsoon Technology has successfully achieved support-free technology for special structures such as horizontal circular holes and inverted cones.

Support-free technology allows the production of complex geometries without the need for additional support structures. This innovation is particularly beneficial for creating intricate designs, such as horizontal circular holes and inverted cones, which are often challenging to manufacture using traditional methods.

Support-free technology not only reduces material waste but also minimizes post-processing time and costs associated with removing supports. This capability enhances design freedom, enabling engineers and designers to explore more innovative solutions and optimize parts for performance and weight reduction.

Advances in Suspended Structures and Support-Free Printing

The smooth formation of parts is a fundamental requirement in additive manufacturing. However, the rapid cooling rates associated with metal powder bed fusion technology can create significant internal stresses during the forming process, leading to deformation of the parts. This issue is particularly pronounced in suspended structures, where warping can result in printing failures—an ongoing challenge for designers.

Thanks to relentless innovation and independent research and development, Farsoon Hi-Tech, a leader in industrial 3D printing, has tackled these technical hurdles head-on. They’ve successfully mastered the creation of complex structures like inverted cones and horizontal circular holes. Notably, they can achieve an infinite height for inverted cone structures with angles between 20° and 25°. Additionally, they can form horizontal circular holes up to 50mm in diameter without the need for support.

Metal additive manufacturing faces support design challenges

A well-thought-out structural design and the right forming process are crucial for achieving smooth part production. In metal additive manufacturing, creating suspended structures often requires additional support, particularly in areas with a low-hanging angle. Typically, support structures are added to any suspended sections that have an inclination of less than 45 degrees to minimize the risk of failure during the printing process.

However, using supports comes with its own set of challenges. For starters, adding supports means consuming extra powder material, which not only prolongs printing time but also complicates post-processing efforts. Some supports can be difficult or even impossible to remove without damaging the final part, rendering it unusable.

To tackle these issues, designers must carefully consider the unique characteristics of additive manufacturing and make structural adjustments to reduce the need for supports while ensuring they remain removable. This can impose additional constraints on the design process.

Given these challenges, it’s essential to refine the forming process and improve the capability of materials and techniques for low-angle formations. Enhancing these aspects can significantly streamline production and lead to better outcomes in metal additive manufacturing.

Special structure to achieve no support

Farsoon understands that the forming capability in additive manufacturing is heavily influenced by factors like material choice, layer thickness, and process parameters. Interestingly, even structural parts with the same inclination angle can present varying degrees of forming difficulty. For instance, creating an inverted cone is generally more challenging than forming a right hollow cone, despite their identical angles.

This highlights the importance for material and process developers to establish clear verification standards for forming capabilities. Farsoon has dedicated significant resources to forward-thinking research and development aimed at optimizing material forming processes. With years of technical expertise and innovative breakthroughs under their belt, they’ve developed proprietary slicing software that employs adaptive intelligent scanning strategies. This allows for precise control over energy input and localized heating during production. As a result, Farsoon has significantly enhanced forming capabilities while maintaining part density, outperforming traditional scanning technologies.

At Farsoon High-Tech, the team is committed to continuous innovation and independent research and development. They have successfully addressed the technical challenges associated with forming complex structures, such as inverted cones and horizontal circular holes. Their latest breakthrough enables the infinite height forming of inverted cone structures with inclination angles ranging from 20° to 25°. Additionally, they can create horizontal circular holes up to 50mm in diameter without the need for support.

Farsoon’s process optimization not only reduces the number of supports required for these intricate parts but also enhances design flexibility. This advancement allows clients to push the boundaries of their workpiece designs while simplifying post-processing requirements. With Farsoon, customers are not just accessing advanced technology; they are gaining the freedom to innovate.

More than 10 applications have been mass-produced

The low-support technology has been applied to dozens of workpieces and achieved mass production. The materials include titanium alloy, high-temperature alloy, aluminum alloy, stainless steel, etc. Typical applications include fuel tanks, closed impellers, valve bodies, nozzles and other parts, and the maximum size of the workpiece exceeds 450mm.

Three major advantages of low support/no support technology

Cut production and post-processing time while slashing costs. For instance, when producing an IN718 closed impeller with a diameter of about 130mm and a height of around 50mm, you can reduce printing time by 33% and lower costs by over 25%. Parts that require more supports can see even greater savings in both time and expenses.

Enhance your product quality by minimizing metallurgical defects that often arise at the junction where supports meet the workpiece. When you remove those supports, the workpiece itself can be vulnerable to damage. Plus, any debris left behind can easily infiltrate narrow structures like flow channels, leading to unwanted material buildup. By cutting down on the amount of support needed, you can significantly mitigate these issues and boost the overall integrity of your parts.

Unlock new design possibilities! Say goodbye to the old 45° forming angle constraint and expand your creative horizons. Take small parts with intricate inner cavity structures, for instance. Traditional printing methods often force you to tweak your designs or pile on excessive support, which can lead to local deformations in those delicate areas. By embracing a support-free strategy, you can achieve smooth, flawless formations without compromising your design integrity. Let your creativity flow!

Metal additive manufacturing technology still has great potential to be tapped

Farsoon will continue to conduct in-depth research and exploration of the potential of metal additive manufacturing technology and innovative processes to further unleash its innovative vitality and development space.

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Guide to Understanding SLA (Stereolithography) 3D printing

Ashkhen — Mon, 01 Apr 2024 10:19:12 +0000

As the range of available technologies continues to expand, it’s natural that more questions arise. That’s why the Additive Plus team is here to provide you with guidance on when to use SLA technology for your projects.
SLA technology, also known as Stereolithography, is a well-established method for prototyping and low-volume manufacturing.

So, what exactly is SLA technology? It’s a 3D printing technique that was developed by 3D Systems in the 1970s, and it was the first industrial-grade approach to 3D printing. The maturity of this technology is crucial, particularly given the numerous alternatives
available for different materials. Its greatest strength lies precisely in its maturity.

How does SLA technology work?

SLA technology uses a laser which is in the ultraviolet spectrum around 355nm, to target a thin >0.1mm layer of photosensitive resin. Photopolymerization occurs when the laser hits the resin and it solidifies. By solidifying layer by layer of resin, it is possible to create complex geometries with an extremely high degree of precision.

What are the advantages of SLA printing?

Higher level of detail compared to other 3D printing technologies: Resolution of 0.02mm in XY and 0.13mm in Z.

Extensive range of materials comparable to technologies like FFF, including polymeric resins such as ABS-like, Nylon-like, and Rubber,-like as well as other resins commonly used in industries such as Wax, Ceramic, and Metal.

Ideal technology for both very small parts in jewelry-making and large-scale pieces in fields like animation, sculpture, and automotive.

Very fast printing speed; SLA technology can achieve 3D prints in remarkably quick times
compared to other manufacturing methods.

Smooth surface finish that eliminates the need for complicated post-processing.

How does this technology compare to others?

It is important to consider the strengths and limitations of each method. While each technology has its own unique applications and benefits, it’s worth noting that this comparison is not meant to suggest that one technology is superior to another in every aspect. Rather, we include it to emphasize the strengths of each technology.

Resolution and precision

SLA is a printing process that is known for its high resolution and precision. This makes it the perfect choice for printing designs that require fine details and smooth surfaces.

FFF, on the other hand, generally offers lower resolution compared to SLA. As a result, the surfaces may be rougher, and the details may be less defined.

SLS, another popular printing process, provides good resolution and precision, although it may vary depending on the machine’s setup. Generally, it offers better resolution than FDM but may not be as high as SLA.

Materials

SLA: It uses liquid resins that can offer a wide range of properties such as flexibility, hardness, and transparency.

FDM: It primarily uses thermoplastic filaments, which limits the variety of materials available compared to SLA.

SLS: It can use a variety of thermoplastic powders, allowing it to print in a broader range of materials compared to FDM, although the variety may be more limited than that of SLA.

FDM

SLA

SLS

Printing time

SLA: It can have faster printing times and achieve more details due to its high resolution and quick curing process. More lasers can be added to the process to achieve higher printing speeds while maintaining high resolution.

FDM: Generally, it has longer printing times due to its layer deposition process, and depends on 1 extrusion head for all the process.

SLS: Printing times can vary depending on the size and complexity of the part but tend to be in the mid-range compared to SLA and FDM. More lasers can also be added to this process to improve printing speed. However, the productivity of SLS is unbeatable thanks to the possibility of printing without supports and the ability to nest as many parts as the build volume allow to.

Post-processing

SLA: Printed parts typically require minimal post-processing in terms of support removal and sanding, as the surfaces are usually smooth directly from the printer.

FDM: Often requires more post-processing to remove layer marks and supports, which may require sanding and additional finishing.

SLS: May require less post-processing than FDM but more than SLA, as parts may have arougher surface texture.

If you require more information about SLA technology or any other 3D printing technology, Additive Plus can provide complete assistance ranging from design and prototyping to high-volume manufacturing.
Additive Plus is an expert in SLA technology, having been in the industry for over 10 years and installed dozens of SLA printers in the United States.
At Additive Plus, we offer 3D printing services in SLA and distribute the Kings 3D printing systems in the United States. We work with large-format parts in our plant in Santa Fe Springs, CA, and produce on-demand batches of parts with excellent quality with short lead times.
We have a wide range of materials for SLA printing that ensure excellent surface finish, combined with consistent and highly accurate dimensional accuracy for engineering and design projects. We also provide comprehensive solutions from CAD design, 3D scanning, and 3D printing.

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Pushing the Boundaries 3DCERAM’s Additive Manufacturing Technology Empowering New Space.

Ashkhen — Fri, 29 Mar 2024 13:15:13 +0000

Explore tailored solutions for Aerospace part development and production, and learn how ceramic materials are making a significant impact in this dynamic industry. Discover the diverse range of ceramic solutions available in the US market through Additive Plus and 3DCeram.

The aerospace industry is leveraging additive manufacturing, specifically 3D ceramic printing, to enhance equipment performance and streamline development processes.

3DCeram provides tools to integrate 3D printing solutions into you projects for manufacting in-house ceramic parts.

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