Laser re-manufacturing and large-scale metal 3D printing

MX3D is one of the industry leaders in large-scale Metal AM. Since 2014, they have been showcasing their technology through various projects like the MX3D Bridge, the Robot Arm and the Takenaka Connector.
In early 2021, MX3D launched a complete robotic Metal AM system called the M1. Connected with the WAAM dedicated software platform MetalXL, MX3D opens the doors to additive manufacturing for high impact industries like Oil & Gas, Maritime and Tooling.
During the presentation, the state-of-the-art of Wire Arc Additive Manufacturing (large-scale metal AM) will be discussed both from a technology as well as a business level.

Laser cutting and laser welding are well known as industrial laser processes. A range of other laser processing technologies has been matured and joint in one machine setup, which will be presented. Measurements during processing becomes important for process control and is included in the system. Here laser technologies for pre, inline and post sensing is an excellent tool and various systems and applications will be presented.

FORCE Technology has been engaged with laser materials processing for more than 35 years. Laser surface treatment, laser cladding, inverse machining, laser re-manufacturing, additive manufacturing and latest laser 3D-printing are some of the phrases that, over time, often are denominations used in relation to basically the same technology. Laser technology-based 3D printing and re-manufacturing of new and defect components is developing into a huge market. Intensive R&D activities are carried out at universities, research centers and at private enterprises. Just recently, FORCE Technology has invested in a new installation related to mentioned technology, tailored for the handling and preparation of large scale metal components.
This presentation will cover equipment, typical applications and present activities.

GTV is an experienced manufacturer of special machinery and provider of complete solutions in the field of thermal spraying and laser cladding.
The presentation will show the product spectrum, which includes complete flexible turn-key centers for coating and 3D component production. Integrated sensors permit automatic adjustment of laser power, edge detection for near net shape cladding applications and in-situ characterization of powder flow stability. Also, the geometry of the powder stream exiting the powder nozzle can be measured. Besides the benefits of these features in realized centers, we will look at the capability of flexible integration into complete production lines including data mining.

DMG MORI, a global company with over 20 years’ experience with additive manufacturing of metal parts, offers two kinds of technologies within the field. With different machine sizes in the powder nozzle (DED) and the powder bed technology (SLM), they represent different technologies for many different applications in the field.

This talk will give an overview of the DMG MORI additive manufacturing product portfolio and show how hybrid manufacturing (milling and additive operations) and graded materials in the context of the Lasertec 3D series (powder nozzle) can open up for manufacturing possibilities.

Furthermore, case stories for DED and SLM applications will show the potential of AM and how it enables optimization of the manufacturing process and products (e.g. reduction of lead and delivery times, improved product performance due to new designs and material changes).

The most common feedstock for metal Additive Manufacturing (AM) are fine metal powders that are consolidated to form a net-shape component. Metal AM components across multiple length scales are utilized in functional applications in the aerospace, tooling, biomedical and energy sectors. As the demand for metal AM powders is increasing, it is necessary to find sustainable methods for powder production. Spray forming is a molten-spray atomization process that can start with scrap and produce an ingot together with fine metal powders. Pilot studies on the fine metal powders (also called overspray) indicated the suitability of the overspray for small and large scale AM.

The presentation will focus on a circular ecosystem to convert scrap into useful ingots and powders. Two powder-based AM technologies namely laser powder bed fusion (small-scale) and direct energy deposition (large-scale) are utilized to demonstrate the application of hybrid AM using both the ingots and powders to make functional components. The components that are made primarily from the ingots can subsequently be repaired using the 1:1 compatible powders manufactured in the same production, thus vastly improving the lifetime of existing components. At the end-of-life of the components, they can be recycled straight back into the spray forming plant to produce high-quality ingots and powders, thus enabling a sustainable circular ecosystem.

Additive manufacturing is entering the oil & gas and maritime industries with the promise of design freedom, optimization and reduction of lead time. However, there are limited standards available for quality assurance of additive manufactured parts. Together with the industry, DNV develops standards and recommended practices to ensure that the industry can utilize the benefits of AM, while still operating safely.
In this presentation, DNV will present how these standards are developed, ongoing initiatives, and the newest addition to the AM standard portfolio.