Old 04-05-2013, 05:36 AM #1
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Default Certified Metallic Components using Electron Beam Melting

Hi all,

I just wanted to share a couple images of some parts I made at work. My company builds parts primarily out of 6Al-4V Titanium for the Aerospace industry and many other large entities using additive manufacturing. Additive manufacturing for those of you who are not familiar is more commonly referred to as 3D printing.

We take a CAD file (3D image) and slice it into many horizontal layers which we then upload to the machine. In a nutshell, a chamber under vacuum utilizes an electron beam to melt one layer of titanium powder (~50 microns) at a time. From the machine the parts go to a "grit blaster" style cabinet to recycle the unsintered powder and reveal the parts inside.

How sick would a 3D printed Aerospace grade Titanium Host be?! lol. Surely some of you know 3ds max or maya.. somebody send me a file!





*Note there is an identical ball inside of the large ball.


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Old 04-05-2013, 06:12 AM #2
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Default Re: Certified Metallic Components using Electron Beam Melting

This is REALLY cool! 3D printing boggles my mind man!
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Old 04-05-2013, 06:27 AM #3
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Default Re: Certified Metallic Components using Electron Beam Melting

How much would you charge? I guess it would depend on volume?
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Old 04-05-2013, 06:31 AM #4
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Default Re: Certified Metallic Components using Electron Beam Melting

What do you need? STL? Might be able to make a quick host in CAD.

That's some pretty awesome equipment you have access to!
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Old 04-05-2013, 03:26 PM #5
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Default Re: Certified Metallic Components using Electron Beam Melting

Welcome fr...fr... friend.
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Old 04-05-2013, 04:16 PM #6
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Default Re: Certified Metallic Components using Electron Beam Melting

Yes, it would depend on volume but if I were to make a host I would say it's for me and the cost would drop a ton.

If you make a host in CAD, yes .STL is exactly what I use.. let me know. I'm sure I can throw it in with another build
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Old 04-05-2013, 04:51 PM #7
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Default Re: Certified Metallic Components using Electron Beam Melting

WOA!
That is really something!
I've always found 3D printing quite fascinating. The surface appears to be rather rough though. Could it be polished? Also, how's the structural strength?
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Old 04-05-2013, 07:21 PM #8
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Default Re: Certified Metallic Components using Electron Beam Melting

Quote:
Originally Posted by Tw15t3r View Post
Also, how's the structural strength?
It is Aerospace Grade Titanium, I am gonna toss out a guess that it is pretty structurally strong
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Old 04-05-2013, 07:29 PM #9
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Default Re: Certified Metallic Components using Electron Beam Melting

Twister,

The parts shown were built using 70 micron layers whereas 50 micron would have yielded a better surface finish. You are correct though; the as deposited parts can be a little rough (primarily on the downward facing surfaces). When required by the customer we do have a few methods to smooth it out, and yes just like any metal I've ever worked with you can polish it.

As far as the mechanical properties, that is where the EBM process shines. The properties of the parts are as good as those built from a forging. Very strong.
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Old 04-05-2013, 07:38 PM #10
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Default Re: Certified Metallic Components using Electron Beam Melting

What is it about EBM that makes stronger parts apart from laser sintering?
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Old 04-05-2013, 08:06 PM #11
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Default Re: Certified Metallic Components using Electron Beam Melting

Quite simply, DMLS (Direct Metal Laser Sintering) is doing just that.. sintering. EBM (Electron Beam Melting) is actually fully melting each layer under a high temperature environment.

We don't have a DMLS just yet but we've thought about it. There are pros and cons to both. Laser can achieve roughly 20 micron layers which would give you more detail especially on tiny parts but the parts typically require post processing to give them any decent strength.

I've got a DMLS part here at the office, i'll snap a pic of it. For what we do, the military or other customers need the strongest parts possible so EBM fits the bill. The build chamber on an EBM machine for 6-4Ti is around ~700c and for Gamma titanium the chamber is around 1000c. Because of this the parts must cool down to a maximum of 100c before we can get the parts out. I believe laser, this is not the case.
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Old 04-05-2013, 09:49 PM #12
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Default Re: Certified Metallic Components using Electron Beam Melting

Unfortunately my desktop computer isn't here or I'd make something up...kinda jealous as I really want a host from this. I feel like the rough texture would add a level of "coolness" to it, in the realm of uniqueness. Very cool indeed!
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Old 04-05-2013, 10:13 PM #13
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Default Re: Certified Metallic Components using Electron Beam Melting

Without a doubt, that`s one of the coolest things I`ve EVER seen!

I agree that the "rough" finish would add some "extra coolness" to the thing!
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Old 04-05-2013, 11:00 PM #14
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Default Re: Certified Metallic Components using Electron Beam Melting

If someone does want to design something, please make it more than just a simple cylinder haha. That would really be too easy; you could just use a lathe for that.

I'd have to agree, I would actually like the finish on a host.. maximum grip and durability. I'm still at work but when I get home I will be sure to put up another pic or two.
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Old 04-06-2013, 01:05 AM #15
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Default Re: Certified Metallic Components using Electron Beam Melting

Unfortunately a lot of the really amazing designs I cannot disclose but I did find some more pics. I did manage to snap one of the laser built part but haven't uploaded it yet.. soon.

From Concept..

To Reality.


And a few jets..
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Old 04-06-2013, 04:30 AM #16
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Default Re: Certified Metallic Components using Electron Beam Melting

Words escape me...remember who was here for you from the beginning! lol
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