New Equipment, Additive Manufacturing for Casting Replacement and AM's Next Phase at IMTS 2024: AM Radio #54

Markforged introduced its FX10 metal kit, a hardware package for its FX10 polymer composite 3D printer that enables the machine to print with metal-filled filament as well. Both printers seen here are identical except that one is equipped with this kit and printing green metal parts. 

Formalloy’s DEDSmart Path scanning module premiered at the show, consisting of a line scanner, motion table and software for capturing the alignment and geometry of parts in preparation for directed energy deposition. The module can be installed next to or even inside of the company’s metal DED printers. 

In the DEDSmart Path demo running at the show, the system scanned a series of turbine blades and developed tool paths based on this data. The module helps reduce setup time and ensure accuracy for operations such as feature addition, cladding or part repair. 

The Stratasys F3300 FDM printer offers different deposition heads and supports larger spools of material for longer, more production-focused builds. 

Launched at IMTS 2024, the Stratasys Origin 2 builds on the DLP technology originally developed before the Origin acquisition, but offers a notably lower price point thanks to reengineering. 

Inside the One Click Metal BoldSeries laser powder bed fusion 3D printer. The green handles indicate where the operator needs to interact with the machine, to load/unload powder cartridges and the build module itself. 

One Click Metal’s standard build module offers an envelope of about 6" × 6" × 6". A larger module (center) enables builds up to about 8", while the smaller lab module supports test builds and applications where keeping the amount of powder used low is advantageous.

CNC turning equipment supplier Index is a majority investor in One Click Metal and exploring the use of this platform to produce parts for its products, such as this slider trolley for a barfeeder which was redesigned for LPBF.

EOS showcased its dual-setup system for laser powder bed fusion, which automates the process of changing out build modules so that production can continue uninterrupted and without human intervention. 

Mazak showed advances in its hot wire metal deposition machine for hybrid manufacturing. 

The new Mazak hybrid reduces the laser power from 6 to 4 kilowatts and the fiber size for the laser from 600 to 300 microns, for an overall increase in power density. These changes mean a small sacrifice in cycle time, but finer control in deposition along with a lower price for the machine. 

Spee3D is seeing interest in its cold spray platform for casting replacement applications such as this housing, printed from nickel aluminum bronze. One result of interest in 3D printing as a casting alternative is rising demand for materials like this that are not yet common in AM. 

In this cell within the Emerging Technology Center (ETC), Oak Ridge National Laboratory (ORNL) demonstrates how 3D printing, machining, part heating and scanning can be consolidated into one system with a flexible workflow to deliver metal parts more efficiently. 

DED 3D printer supplier Meltio sees ample opportunity for wire-based additive to aid the casting supply chain. Sample parts in its booth demonstrate how DED can deliver near-net-shape components similar to castings. 

While casting replacement is more often associated with DED and LPBF processes, Colibrium Additive (the new name for what was GE Additive) exhibited examples of complex binder jet parts that could play a similar role as casting alternatives. 

Hybrid Manufacturing Technologies exhibited its 45° powder deposition head for hybrid manufacturing for the first time at IMTS 2024. The typical powder deposition profile with a straight-down head can result in excess material application; this angled head offers a different approach to the workpiece for cleaner edges on features such as the shoulder added to the bearing pictured in this display case. 

Penn United has previously exhibited its grinding technology at IMTS, but this year chose to highlight its laser powder bed fusion services within the Additive Sector. The company uses LPBF to manufacture metal parts (often, as an alternative to castings and forgings) that it then machines to finished form. Example parts in the booth included this trim stack for preventing cavitation within valves. 

Contract manufacturer 3DEO showcased parts made from copper, a material now supported by its Intelligent Layering process. Incoming CEO Scott Dennis spoke about the company’s drive for partnership with its customers, and the need to overcome potential “nervousness” about implementing additive manufacturing. 

Desktop Metal saw renewed interest in its Studio System for metal extrusion, a platform that AM newcomers are finding accessible for beginning with metal 3D printing.