Printed Part Eliminates Assembly, Improves Cooling

December 3, 2019

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Largest formnext So Far
Formnext 2019, held last month in Frankfurt, Germany, welcomed 34,532 visitors representing the aerospace, automotive, energy, medical and other additive manufacturing (AM) markets, and 852 exhibitors from more than 30 nations. The numbers represent a 28-percent jump in attendance and a 35-percent gain in exhibitors over last year, and position the 2019 edition as the largest formnext yet.

“In its fifth year, formnext continues its impressive success story,” says Sascha F. Wenzler, vice president-formnext at event organizer Mesago Messe Frankfurt GmbH. “AM definitely has arrived, and together with our enormously dynamic industry, we will continue to accompany, support and advance this development as a trade-fair organizer.”

Formnext 2020 will take place November 10-13, 2020, in Frankfurt.

ASME image
You Are the Next Generation of AM Engineers
Revenue from 3D printing is expected to nearly double by 2020. That means employers and managers are looking for a well-trained and skilled workforce to integrate this technology into their workplace. With the help of ASME, that will be you. Enter code: DFAMINTRO

Trumpf additive image
Seen at formnext: Printed Part Eliminates Assembly, Improves Cooling
Demonstrating at formnext the efficacy of metal AM, Dr. Klaus Parey, managing director of Trumpf Additive Manufacturing, holds a metal AM part previously produced via assembly of 10 separate parts—that component is on the table. Besides cutting component cost by 30 percent, design-and-build capabilities inherent in AM yielded optimal cooling channels that improve the part's cooling efficiency by 20 percent.

Register for AMUG, the Signature North American AM Users Event
Registration is open for the Additive Manufacturing Users Group (AMUG) 2020 Education & Training Conference, March 22–26 in Chicago, IL. The conference, set for its 32nd year, targets owners and operators of industrial AM technologies used for professional purposes, and attracts users all along the experience spectrum.

Directed Energy Deposition image
WATCH: Directed Energy Deposition
Courtesy of BeAM, take a close look at directed energy deposition, and how this AM technology can build and fix. The video shows what was in store for visitors to formnext, where BeAM exhibited along with AddUp.

8 Must-Ask Questions for Your AM Metal Powder Supplier
The right metal powders help keep your operation productive. So, don't compromise when choosing a supplier. Look for expertise, capacity and quality that match your vision for a growing operation. This free AM Metal Powder Buyers Guide has key questions to guide your conversations with metal powder suppliers.
Download now.

Coming PC Game Offers Serious AM Training
At formnext, AddUp teased a unique video game, AddUp Adventure, which offers learning opportunities across the AM spectrum, with mini-games, tutorials and more included. Take a sneak peak.

Markforged head
Seen at formnext: Inhouse Printing Slashes Clip-Build Lead Time and Cost
Nieka Systems, courtesy of the Markforged Metal X, now conducts small-batch Inconel manufacturing inhouse. No longer relying on a direct metal laser sintering print service, the company was able to reduce the manufacturing cost of this clip from $311 to $23, and cut lead time from 28 to 3 days.

Spee3D image
WATCH: Spee3D Builds with Speed at formnext
Spee3D printed a 1-kg copper sledgehammer in 10 minutes, 2 seconds, live on the show floor at formnext. Spee3D printers use supersonic deposition in which a rocket nozzle accelerates air to three times the speed of sound. Injected powders deposit onto a substrate attached to a six-axis robotic arm. In this process, the sheer kinetic energy of the particles causes the powders to bind together to form a high-density part with normal metallurgical properties, according to company officials, who claim that this process enables metal parts to be printed 100 to 1000 times faster than other printing methods.

“We want to see development in the industry, and we look forward to pushing our technology even faster,” explains Byron Kennedy, co-founder and CEO of Spee3D.

TruPrint 3000: Made for Production
TRUMPF’s TruPrint 3000 powder bed fusion system is designed for production. Utilization is increased with external part and powder handling, with time between build jobs reduced and operator safety improved. The large build volume, variable spot size, high preheat temperatures and dual supply cylinders provide advantages that are unmatched.

Materialise image
Seen at formnext: Metal Suction Grippers
At formnext, Materialise highlighted its AM design-to-production capabilities, including redevelopment of a suction gripper. Materialise engineers created a part using less material, eliminating machining steps and integrating internal channels. The resulting part improvements: 94 percent lighter, half the production cost and better suction. During 3DMP’s visit, Jurgen Laudus, vice president of Materialise's manufacturing segment, reported October groundbreaking for a new facility in Bremen, Germany, for AM of metal industrial parts. Expected completion: early 2021.

Free Webinar: Selecting Parts for Additive Manufacturing
As metal AM continues to expand as a viable production process, many companies are assessing the viability of producing parts via the selective laser melting. In 3D Metal Printing’s free webinar, Selecting Parts for Additive Manufacturing, the SLM Solutions North America application-engineering team discusses what types of parts, features and geometries are best suited to be optimized for AM, and provides tips on what may make the process unfeasible. Attendees gain an overview of how to assess their components in order to implement a metal AM strategy.

ASME’s Advanced Manufacturing & Repair for Gas Turbines Symposium Brings Together the Who’s Who of this Specialty User Group
The Advanced Manufacturing & Repair for Gas Turbines event is dedicated to advanced manufacturing for gas turbines and promises to reveal successful best practices and new technologies to improve efficiencies and reduce maintenance costs. Join us to learn, share and build relationships when the full supply chain of companies involved with advanced manufacturing for gas turbines come together in March.

GE Additive image
WATCH: GE Additive’s Additive Tunnel at formnext
Courtesy of its display at formnext, GE Additive provides a recap of the company’s AM journey, from machines to materials, services and machine software.

DMG Mori image
Seen at formnext: Steel Manifold via Hybrid Manufacturing
Built in a Lasertec 125 3D hybrid machine from DMG Mori, this stainless steel manifold, measuring 130 by 300 by 400 mm, was produced in 28 hours. The machine combines laser metal deposition with five-axis milling to build and repair parts in diameters to 1250 mm, heights to 745 mm and weights to 2000 kg.

Industry News
Today’s News
Study Compares Resource Consumption of Additive and Conventional Manufacturing
Accurate Brazing Adds Second HIP
Trans Machine Technologies Acquires Assets of Wright Metal Products
Oerlikon AM and Siemens AG Partner to Digitize Additive Manufacturing

Fall 2019
In This Issue
Heat Treatment Delivers More-Consistent Powder
Enabling powder to flow continuously and smoothly, via proper processing that includes drying and tumble blending, is a must for reliable 3D printing production.

Tackling a Mountain of AM Challenges in The Rockies
New AM education programs and a high-powered consortium position Colorado School of Mines as a 3D printing teaching and research leader.

Coming in 3DMP's Winter 2020 Issue
Previews Galore—As the 2020 AM-event season takes off, 3DMP provides insight into what you’ll see at AeroDef Manufacturing, March 17-18; AMUG, March 22-26; and RAPID + TCT, April 20-23.

Software Roundup—Find out what’s new in software for AM design, simulation, process control, production and more.

Video Marketing
Need Video to Support Your Website and Social Media Platforms?
Do you need new video content for your website and social-media platforms? Looking for a professional videographer to produce a virtual tour of your facilities, or to capture a key specialty process that provides your company with a competitive advantage? Let MetalForming magazine help.  Now available, in partnership with Toth Media, LLC:
  • Company profile or promotional video production
  • Product or service promotional or educational video development
  • Indoor/outdoor drone videography
  • Photography; and more
Request a quote today—e-mail Brad Kuvin.

PMA Services Inc

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Industry-Related Terms: Bed, Download, Form, LASER, Lead Time, Spectrum, Stainless Steel, Substrate
View Glossary of Metalforming Terms



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