Roush Takes Delivery of Large-Scale Powder-Bed System

Roush, a product development supplier headquartered in Livonia, Michigan, has become the first supplier in North America with the Xline 2000R, a large-scale powder-bed metal additive system. 

Acquired by GE Additive in 2016, the Xline 2000R from Concept Laser has a build envelope measuring 800 × 400 × 500 mm for large-scale production, such as engine blocks. The machine includes a rotating platform that allows two build modules to be used reciprocally.

The company has expanded its additive manufacturing capabilities with equipment to benefit multiple industries, including aerospace, automotive, defense, energy, entertainment, medical and consumer products. In addition to Xline 2000R, Roush’s latest investment in additive manufacturing adds new fused deposition modeling with large-frame machines from Stratasys; direct metal laser melting equipment from EOS; and capabilities in design for additive and topology optimization to its existing stereolithography, selective laser sintering and rapid prototyping services.

“During the past year, Roush has invested millions of dollars in new additive manufacturing equipment to expand our reach into more industries,” says Dean Massab, executive vice president of business development for Roush Enterprises. “Investing in the latest additive manufacturing technology continues our commitment to innovative, high-performance solutions—from concept maturation and optimization, all the way through to hardware integration and development.”

Roush has been providing additive manufacturing and rapid prototyping services for more than 15 years. The company’s services that support additive manufacturing capabilities include 3D scanning; metallurgical testing and inspection; machining, fabrication and assembly; and full-spectrum design engineering. Increasing these additive manufacturing capabilities and topology optimization technologies complement other Roush offerings, such as performance testing, product design and advanced engineering.

“Roush is a single-source product development supplier for customers,” says Brandy Badami, business development manager, additive manufacturing for Roush. “Our unique advantage in the additive manufacturing industry allows Roush to provide seamlessly integrated services like no one else can.”

Roush’s new 3D printing capabilities also include working with advanced materials, such as production-grade thermoplastics and carbon fiber-filled nylon material. Aerospace industry customers will benefit from Ultem materials (used in production aircraft components) with their high heat and chemical resistance, and certifications in flame, smoke and toxicity. The automotive industry will benefit from actual production material (ABS, PC, PPSF, etc.) for prototype and production parts without the need for tooling. And military and racing industry customers will benefit from the lightweight, mechanical properties of the carbon-fiber-filled nylon material for high performance components.

Also with these advanced materials, Roush can 3D print sacrificial tooling for composite components and parts. This allows for composite parts to have exotic geometries that cannot be manufactured by traditional means.

“Our clients are achieving market dominance faster and with better performance with these expanded opportunities in additive manufacturing combined with Roush’s leading expertise in innovative design, engineering and development services,” says Badami.