16-seiter_EN 2013.indd

Selective Laser Melting
Visions become Reality
2
In 1990, the physicists Dr. Matthias Fockele and
Dr. Dieter Schwarze founded the F&S company. As
pioneers of Rapid Prototyping, they were globally among the first to develop and produce stereolithography equipment (STL) for the production of
plastic prototypes.
In 1995, the company started the development of
SLMTM technology (Selective Laser Melting) for the
production of components made of metallic materials
in cooperation with ILT Aachen. As early as 1997, the
first patents were applied for. In 1999, the company
delivered the world’s first SLMTM machine for metals to
the Forschungs-zentrum Karlsruhe. In 2004, Dr. Matthias Fockele founded ReaLizer GmbH, another enterprise which focuses on the development and production of SLMTM machines for the manufacture of metal
workpieces.
3
Innovation and Partnership
As a technology leader in the area of Selective Laser Melting, ReaLizer GmbH was the first
company to develop an innovative and novel technology – a technology which has been
in practical use for more than ten years now. Creativity and innovation, combined with
our wealth of experience, allows us to continually optimise and develop this technology.
We attach particular importance to a partnership based co-operation with our
customers. They in turn appreciate our dedication. We don’t waste time with lengthy
discussions when it is time to find a solution, we take creative, committed and positive actions.
Many tasks and objectives can only be realized in close and
trusting co-operation with our customers. In each case,
absolute confidentiality during the exchange of information and knowledge is assured. Because a productive cooperation is not a one-way street, we welcome our customers close involvement in the problem solving and
development processes.
“The only way to attain our goals
is to proceed together…”
4
SLMTM – The Technology
Layer by layer on the way
to the functional workpiece
Selective Laser Melting (SLMTM) is an additive manufacturing method in which the
desired components are produced directly from 3D CAD data. Using standard format STL
files highly complex parts can be produced from a wide range of metallic materials.
With the SLMTM method, the workpiece is constructed in a three-dimensional layered
structure. To accomplish this, the metal is applied in thin layers of very fine powder and
melted onto those areas where the workpiece is required to be constructed. Depending
on the surface quality and production speed requirements, the powder is automatically
applied with layer thicknesses of 20 to 100 µm. A powerful fibre laser then selectively
melts the designated areas. Optimum focusing provides the laser beam with a very high
power density which melts the material with extreme precision. This results in workpieces with an absolute density being produced with wall thicknesses down to 40 µm.
When the melting process is finished for the particular layer,
by the respective thickness,
and another layer of powx-y Scanner Laser
der is applied. The workpiece
7
1
is constructed layer by layer
2
in this manner. The duration
6
5
3
of the process, which takes
3
place in an enclosed inert gas
4
atmosphere, is dependent on
the amount of material used
1 Inert gas (Argon)
and the number of layers –
2 Recoater (or wiper)
rather than the complexity of
3 Powder container
the component.
4 Height adjustable
work platform
the platform is lowered
Focus Ø
10-50 µm

7
5
5 SLMTM component
6 Powder bed
7 minimum laser
focus
6
5
The layer structure facilitates the production of highly
complex lattice and honeycomb structures which cannot be produced using other methods. With the SLMTM
process, the component design can be optimised for
strength with the advantage of weight saving that
only this type of technology can deliver.
Components of absolute integrity, durability, strength and quality are produced by
means of SLMTM, the material properties of which are nearly equal to those of conventionally produced components. Depending on the intended use and just like more conventionally produced components, they can be reworked using any other method.
This is what makes SLMTM technology
a sensible alternative...
Optimized material usage
• When a functional metal component has to be produced
from three-dimensional construction data in the shortest possible time. SLMTM makes prototypes available
using the CAD STL quickly and without the time constraints experienced by more
conventional processes. This process is not only faster, but also the most economic
way to generate a perfectly functional sample.
• If complex components with hollow or lattice structures cannot be manufactured or
only manufactured with very complex methods using conventional processes, SLMTM
technology becomes the cost effective solution.
• When only a limited number or unique of components are to be produced.
• Compared to the lost-wax casting process, immediate SLM production can often
prove more cost effective.
6
ReaLizer in Action
SLM 50
for manufacturing
Metal Components
With the SLM 50, ReaLizer delivers the Industry‘s first SLMTM desktop machine for
manufacturing components made of metal. The desktop device has been designed for
the manufacturing of components with a diameter of up to 70 mm and a height of up to
40 mm.
Applications
An important application for the SLM 50 is the manufacturing of crown frameworks,
bridge frameworks or brackets made of cobalt-chrome and gold alloys for the Dental
Industry. Following moulding by the dentist, initially a conventional dental die is prepared. The dental technician scans the model and prepares the data for the individual
components
using special CAD software. Based on this 3D data, the SLM 50 produces exactly
fitting dental components – quickly and of high quality. The components are absolutely
true to size, homogeneous and require only minimal post processing. On the construction platform with a diameter of 70 mm, up to 40 individual components can be manufactured simultaneously.
Another field of application for the SLM 50 is the manufacture of jewellery. Many
design ideas, that cannot be realized with conventional jewellery casting, become possible with the new SLM-technique. The new fabrication possibility of hollow parts for the
jewellery industry is especially attractive. An important advantage of the SLM 50 is the
small amount of material needed for the manufacturing of jewellery made of expensive
precious metals.
The optional integrated stereo microscope offers universities and research institutions fantastic opportunities for process monitoring.universities and research institutions optimal opportunities for process monitoring.
Displayed jewelry parts designed by Stilnovo
7
Specifications
Construction volume Platform diameter 70 mm, max. construction height 40 mm
Thickness of layers
Laser type
Power supply
20-50 µm
Fibre laser 20 to 120 W
16A, 230V
Power consumption
1.0 KW
Argon consumption
approx. 30 Liter/h
Dimensions
Weight
W800 x D700 x H500 mm
approx. 120 kg
Software
ReaLizer Control Software
Materials
Tool steel, titanium, titanium V4, aluminium,
cobalt chrome, stainless steel, Inconel, gold alloys
others on request
8
ReaLizer in Action
SLM 100
Precision and Perfection
The ReaLizer SLM 100 is designed specifically for the production of „smaller“
components where high precision and surface quality are of utmost importance.
This machine has a 100 mm high construction area with work platform dimensions of
125x125 mm. This base area permits the use of optics to focus the diameter of the laser
beam down to 20 µm. With the corresponding scan strategy, this machine can produce
components with delicate structures with a minimum wall thickness down to 60 µm and
with high surface quality.
With its compact design and ergonomically designed workstation, the ReaLizer SLM 100 is especially suited for use in
laboratories and similar environments.
9
SLM 100 specifications
Construction volume
Layer thicknesses
Laser type
Power supply
Power input
Argon consumption
Dimensions
Weight
Platform 125 x 125 mm Max.construction height 200 mm
20-100 µm
Fibre laser 50 to 200 W
16A, 400V
1.5 kW
app. 35 litre/h
W900 x D800 x H2400 mm
500 kg
Software
ReaLizer control software
Materials
Tool steel, titanium, titanium V4,
aluminium, cobalt chrome, stainless steel,
Inconel, ceramic materials under development
others on request
10
ReaLizer in Action
SLM 300
The All-Round Talent
The ReaLizer SLM 300 is designed for all-round use – It is suited for laboratories as
well as the industrial production of components.
The construction volume measures 300 mm x 300 mm x 300 mm and offers great
flexibility. The processing area can be utilized to stack several pieces on top of each other
or next to each other, whereby maximising the number of components being processed.
If a high component throughput is the primary requirement then the SLM 300 can also
be equipped with a high-capacity laser with output power up to 1000 W. The standard
minimum laser focus of the machine is 55 µm. ReaLizer also offers a fully automated
sieving machine, with powder extraction system, which optimally recycles the powder
from the processing area. An exchangeable lens module is available as an option for
applications requiring a smaller beam spot size. This option may reduce the available
construction space but allows the laser beam to be focused to 20 µm to produce structures with high surface quality.
The sieving machine
The sieving machine by ReaLizer facilitates the optimal
recycling of excess metal powder. The ReaLizer PS01 is a
fully automated vibration sieving machine with processing
area powder extraction system. Extraction, sieving and
automatic return to a powder container all takes place in a
fully inert gas atmosphere. The powder can then be directly
returned into the work process.
With the stand alone vibration sieving machine ReaLizer
PS02, the extracted excess metal powder can be returned
into the ReaLizer stainless steel powder bottles.
11
SLM 300 specifications
Construction volume
Layer thicknesses
Laser type
Power supply
Power input
Argon consumption
Dimensions
Weight
300 x 300 mm, maximum construction height 300 mm
20-100 µm
Fibre laser 200, 400, 600 or 1000 W
16 A, 400 V
2.5 kW
app. 70 litres/h
W1800 x D1000 x H2200 mm w/o sieving machine
800 kg
Software
ReaLizer control software
Materials
Tool steel, titanium , titanium V4, aluminium,
cobalt chrome, stainless steel, Inconel
others on request
12
SLMTM in action
Versatile, fast, economical
As a rule, SLMTM processes are more economical than conventional processes when
production of unique pieces, customized parts, or small batch quantities are required. In this type of production, the cost benefit is usually higher when the number of
components produced is low, the complexity of the component is high and the material usage is low.
“Great cost benefit in
small volume production“
Selective laser melting facilitates the production of
more complex workpieces that cannot be produced with
other production processes or only with great difficulty.
This way, delicate lattice, mesh or net structures, porous
structures, or channels running through the workpiece in
irregular patterns can be produced without a problem.
In the SLMTM machines by ReaLizer, functional metal pieces are produced directly from
the CAD construction data quickly and with their mechanical properties equal to that
of more conventionally produced workpieces.
SLMTM technology can also be utilized to rapidly produce customized human implants
from medical 3-D data supplied by a CT or MRT, for example
13
ReaLizer and its customers
Know-how, Service, and Trust
We are happy to assist our customers during the development and implementation of the SLMTM production
“Discover new and innovative
processes. In addition to providing innovative hardpossibilities with us!“
ware and software solutions, we will continue to provide
competent assistance to our customers in the on-going
optimization of the processes.
Within the scope of a cooperative and trusting partnership, we will share
our considerable knowledge of this ground breaking technology with you at any time.
We are pleased to support you with…
• the optimization of process parameters for your application and the materials
utilized,
• developing an optimum solution considering the required surface quality, precision,
and production speed,
• the optimal design of the parts to be produced,
• the start-up phase and capability to achieving the required results, as well as the
development of test methods for quality assurance.
The innovative way
into the future
Chances and possibilities
The future belongs to SLMTM technology; it is faster and more economical than more
conventional processes in many areas. It also enables us to realize many great ideas.
There are no limits to creativity in the development of new component designs.
With the growing number of standardized applications and materials, this innovative
process will continue on its way out of the research labs and development divisions into
the production halls. There are already ReaLizer SLMTM machines which have been integrated into industrial production facilities. Designers from all industries will not only
see the technical possibilities of the SLMTM technology in the construction of metal
parts, but also include this in their plans for future production needs.
After all, Selective Laser Melting is generally more economical and faster when
material volumes and batch sizes are small. What is more, SLMTM technology facilitates
the production of intricate lattice, and hollow honeycomb structures that are impossible to produce with other methods. This alternative technology offers completely new possibilities when the mass of components has to be reduced while
maintaining strength and stability. Human and dental medicine will also find
unique ways for the production of even more effective customized implants
and dental parts with SLMTM technology.
With the advancement of SLMTM technology, even the production of
larger parts, for example in air and space industries, will no longer be
a vision of the future.
15
Available to you on the Internet at
www.realizer.com
ReaLizer GmbH
Hauptstraße 35
33178 Borchen
Germany
Telefon 49 (0) 5251 63232
Telefax 49 (0) 5251 63062
E-Mail
[email protected]