The German research institute Fraunhofer IWS revealed that it is testing a 3D printing system that may be "a thousand times faster" than current mirror-based laser manufacturing technology.
The institute's setup is built around a high-power 13-kilowatt "dynamic beam laser", which is said to be able to quickly generate different energy distribution patterns and accurately print the most demanding materials. According to Andreas Wetzig of Fraunhofer IWS, the technology "breaks the limits of metal 3D printing" and unlocks new alloys for medical, electric vehicles, and aerospace applications.
The newly installed device of Fraunhofer IWS was originally developed by the Israeli company Civan Lasers and is essentially a form of coherent beam combination or "CBC" 3D printing. Considered the "Holy Grail" of high-power laser technology, this method involves splitting the laser into amplifiers to generate multiple coherent rays and then combining them into a powerful single beam.
In the case of Civan Lasers, the company developed a method that uses a small phase shift in part of the beam to modulate its energy distribution pattern. Compared with existing lasers that release most of the energy in the center of the beam, dynamic beam lasers can therefore pattern parts into complex "ring" or "horseshoe" shapes.
In theory, this can already be achieved using beam deflection optics or fast oscillating mirrors, although each realignment takes several milliseconds. However, Civan Lasers' method is faster and can adjust the energy mode of the laser within a few microseconds, so it is possible for the first time to use dynamic beam shaping in industrial-scale metal 3D printing.
Fraunhofer IWS and "ShapeAM"
As part of the "ShapeAM" project, which is part of the broader EU-supported "M-era.Net" project, Civan Lasers has now installed its new self-named project at Fraunhofer IWS’s Dresden plant "CIVAN" system. The ShapeAM team worked with colleagues from welding expert Laser Welding Solutions and stated that its ultimate goal is to develop titanium and aluminum 3D printed parts with "improved material properties."
Specifically, the researchers intend to use dynamic beam shaping to eliminate component defects and overcome many of the existing challenges posed by crack-sensitive materials. In doing so, the team believes that it is also possible to manufacture metal parts with specific application qualities, such as metal parts customized for use in outer space, or implants with enhanced biocompatibility.
To measure the capabilities of dynamic beam lasers, experts at Fraunhofer IWS and Civan Lasers first planned to conduct basic tests on beam profile and materials, and then tried to determine its end use by evaluating its cutting, joining or 3D performance. Printing with alloys that are usually difficult to process Various objects.
Although the project only started in July 2021, Fraunhofer IWS has predicted that CIVAN will provide "faster and more precise control" of the melt pool dynamics during the 3D printing process. In other areas, the institute also predicts that in laser cutting, dynamic beam lasers will prove to be twice as fast as current fiber lasers, while producing burr-free cutting with excellent edge quality.
On September 14, 2021, Fraunhofer IWS will host a webinar where it will discuss its experiments with potential industry and research partners and invite those interested in testing the technology to use CBC lasers for them Own application, provided that any follow-up findings will be announced at the Laser Symposium and ISAM 2021 on December 7-9, 2021.
High power laser 3D printing
Unlike the CBC-based system that was tried out at Fraunhofer IWS, many current metal 3D printers are limited to using single-mode 10 KW lasers. To solve this problem, manufacturers are increasingly equipping their printers with multiple high-power lasers and large capacities to manufacture huge machines with industrial-scale potential applications.
With this in mind, SLM Solutions launched its powerful new NXG XII 600 3D printer on Formnext Connect last year. The system is equipped with 12 1 KW lasers, designed for the mass production of large-size parts in the automotive or aerospace industry, and has attracted the interest of "main European OEMs".
Similarly, Brilliance Technology launched a new powder bed fusion (PBF) 3D printer at TCT Asia 2021, which is equipped with no less than eight 1000W lasers. Farsoon's system provides two settings, including "FS721M-8" and a reduced version of "FS721M", designed to allow users to cost-effectively upgrade their metal 3D printing operations, providing specific automotive, tool, and industrial opportunities.
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The featured image shows an engineer installing Civan Laser's "dynamic beam laser" at the Fraunhofer IWS plant in Dresden. Photo from Fraunhofer IWS.
Paul is a graduate of history and journalism and is keen to find exclusive news about the latest technology news.
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