Technology Advancements and New Locations Propel Additive Manufacturing Industry

The additive manufacturing (AM) industry has been gaining headway with improved deposition rates, digitalization, and new facilities. Below is a summary of AM news from Sciaky Inc., the BMW Group, United Performance Metals, and Velo3D Inc.

Sciaky Inc., Chicago, Ill., a subsidiary of Phillips Service Industries Inc. and provider of metal AM solutions, announced its Electron Beam Additive Manufacturing (EBAM®) process deposited 40 lb (18.14 kg) of titanium per hour. The company states that deposition rate is the highest and fastest in the world for industrial metal 3D printing. The Saint Exupéry Institute for Research in Technology, located in France, achieved EBAM’s high deposition rate while conducting work for its Metallic Advanced Materials for Aeronautics (MAMA) project. Launched in 2019, one of MAMA’s initial goals was combining die forging with metal 3D printing to develop a new process for manufacturing titanium aircraft parts. To date, Sciaky’s EBAM has deposited more than 330 lb (150 kg) of Ti-6AI-4V for three different MAMA applications. Additional projects are planned for 2022 and beyond.

“Sciaky is excited about EBAM’s new deposition rate milestone,” said Scott Phillips, president and CEO of Sciaky Inc. “We are committed to discovering new applications for EBAM that will help manufacturers save significant time and money on part production as well as improve part quality.”

A sample part from Saint Exupéry Institute for Research in Technology’s MAMA project, where Sciaky’s EBAM® technology was utilized.

A project consortium funded by the German Federal Ministry of Education and Research, Bonn, Germany, and led by the BMW Group, Munich, Germany, has industrialized and digitized AM for automotive series processes. The consortium was launched three years ago with small and mid-sized enterprises, large companies, and research institutes. The common goal was to improve metal 3D printing in standard production of cars.

The 12 members of the consortium presented the successful implementation of the Industrialization and Digitalization of Additive Manufacturing (IDAM) project at the BMW Group Additive Manufacturing Campus in Oberschleissheim, Germany, where a digitally connected, fully automated 3D printing production line was set up and prepared for automotive standard production. An additional line is located at GKN Powder Metallurgy in Bonn, Germany.

Around 50,000 components per year, as well as more than 10,000 individual and new parts, can be manufactured cost effectively in common part production by means of 3D printing using laser powder bed fusion.

United Performance Metals, a specialty metals solutions center, unveiled its new AM solutions center in Hamilton, Ohio. The additive center provides new stainless steel, nickel, and titanium build plates customized to any size or machine. The company provides end-to-end supply chain solutions for the AM market from feed stock supply management to finished part manufacturing. It also offers closed-loop refurbishment of existing build plates through additional milling and grinding as well as wire electrical discharge machining (EDM) build plate removal.

The IDAM project has set up a digitally networked, fully automated 3D printing production line and fully integrated it into automotive series production. (©BMW Group)

Velo3D Inc., Campbell, Calif., a metal AM technology company for mission-critical parts, opened its European Technology Center in Augsburg, Germany. The center will allow the company to manage its operations in Europe, host customers for trainings, and conduct meetings. Velo3D’s

European customer success, sales, and support teams will reside in the technology center, which will act as the hub for the company’s efforts in the region and showcase an end-to-end AM solution from the company.

The new technology center is more than 110 sq m (1184 sq ft), with a lab area featuring a Sapphire printer, a showcase of parts that were printed using the company’s technology, offices, and conference rooms.

Velo3D’s European facility will act as the company’s European headquarters with an operating Sapphire printer, demo center, offices, and other facilities.