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Direct Rapid Manufacturing of Metallic Parts – A UK Industry overview 2008
Direct Rapid Manufacturing of Metallic Parts
A UK Industry overview - February 2008
What is Rapid Manufacturing?
Rapid Manufacturing (RM) is the name given to the production of ‘series’ or ‘end-use’ component parts
made using ‘Additive Layer Manufacturing’ (ALM) processes. Traditionally, ALM processes were used
to manufacture prototypes and casting patterns. However, recent advances in ALM technologies and
materials, now allow us to manufacture parts in polymers, ceramics and metals for a variety of
production applications.
How Does Additive Layer Manufacturing Work?
The principle of additive layer manufacturing is relatively
simple. As opposed to machining, where material is
removed from a solid block, or casting where material is
melted and forced into a cavity, additive processes work by
‘building-up’ the required geometry particle-by-particle,
layer-by-layer, from the bottom-up.
Figure 1 – Laser sintering of Cobalt Chrome
powder during the build process within an
MCP Realizer 100 machine
There are many different mechanisms for both generating a
single layer and also for bonding layers together. In some
simple systems, layers are cut from sheet material and
bonded using adhesives or ultrasonic welding type
processes. In other systems, layers are generated by
melting fine powder using a laser or electron beam, and
consolidating the new layer onto the previous layer by
remelting. (See Figure 1) In all, there are over 30 different ALM processes marketed by over 40
different companies around the world. The majority of these systems are however focused on
polymeric materials and not yet metallic’s.
Why is RM becoming so important to the UK Economy?
RM is seen by some as one of the most important emerging technologies that will drive the future
manufacturing economy. One of the most notable advantages of RM is the potential elimination of
tooling. Without the constraints of casting or moulding tools, or machining jigs and fixtures, RM
provides manufacturers the ability to produce cost effective batch sizes of ‘one’, or the ability to
manufacture parts at multiple locations or with multiple product design iterations at no additional cost.
Why is RM different to traditional manufacturing?
Because RM uses layer-wise manufacturing, many of the
traditional Design for Manufacture (DFM) principles no
longer need apply, as parts are not made in tool cavities or
held within fixtures. Therefore, RM components can be
manufactured with no split lines, or with complex internal
and re-entrant features. RM therefore allows for significant
part consolidation, reducing manufacturing, assembly and
inspection costs. (See Figure 2)
RM also allows for the manufacture of topologically
optimized components, producing parts that are
‘manufactured-for-design’ as opposed to ‘designed-formanufacture’.
This can eliminate many secondary
Figure 2 – Complex single piece geometry
manufactured on a powder bed laser
system. The part is an optical lens holder.
Copyright - Econolyst 2008 www.econolyst.co.uk
1
Direct Rapid Manufacturing of Metallic Parts – A UK Industry overview 2008
Copyright - Econolyst 2008 www.econolyst.co.uk
2
manufacturing steps such as internal machining operations
or secondary fabrication. (See Figure 3)
Figure 4 – Replacement classic motor
cycle water pump impeller manufactured
using EOS Direct Metal Laser Sintering
(diameter 50mm)
How will RM affect the traditional supply chain?
In principle, RM can reduce or eliminate many stages of the
traditional supply chain, which reduces lead times, inventory
and supply chain transaction and logistics costs.
Moreover, because RM parts are made using additive
manufacturing technologies, as opposed to subtractive or
formative processes, little if any waste material is generated.
This is particularly true of the newer metallic processing
technologies, which we will discuss later. Additive
manufacturing processes are therefore lean, yet agile,
allowing the manufacture of low volume batches of
component parts, with little manual intervention.
Figure 3 – Topologically optimised diesel
pump housing manufactured using MCP
Selective Laser Melting This part weights
60% less than the original casting
So who is using RM today?
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