Additive Manufacturing with Parallelkinematic Modules: 3DMD Process with Machining of Large Parts
What is the 3DMD Process?
Dynamic Material Deposition (3DMD) combines powder-based laser deposition welding with Additive Manufacturing of metallic components. In this process, a laser melts the material which is then deposited onto a substrate. This method speeds up production, decreases energy consumption, and minimizes warping.
The Challenge of Size in Additive Manufacturing
Additive Manufacturing has a notable limitation: while it produces small parts with high precision, large components often lack detail and quality. The hybrid SigmaTau equipped with a DED (Directed Energy Deposition) or a 3DMD process addresses this issue, enabling economical production of large components without sacrificing precision.
Versatility and Applications of 3DMD
Originally, the 3DMD process was primarily used for coating components. However, its capability to process various alloys and metals through a nozzle-based powder supply makes it extremely versatile. Applications include:
- Protective coatings that extend the lifespan of components
- Specialized surface treatments
- Reinforcement features for lightweight construction, leading to material cost savings
- Repair of components, as well as traditional Additive Manufacturing
Machine Specifications for Optimal 3DMD Performanace
The implementation of the 3DMD process demands machinery that can achieve both rapid operations and meticulous precision, requiring strong stiffness and dynamic capabilities. The SigmaTau robot’s design enables high surface rates of up to 1,000 cm²/min and build rates of up to 600 cm³/h. It is specifically engineered to maintain speed in all directions and reorientations to keep as close to net shape as possible, supporting efficient production.
Precision Manufacturing of large parts: The Integration of 3DMD in the Parallelkinematic Module (PKM)
Together with Cognibotics and technology partner Ponticon, ELHA-MASCHINENBAU has successfully integrated the dynamic material separation process (3DMD) into the PKM. This collaboration has resulted in a versatile system that is able to handle the production and machining of complicated components made from a variety of alloys and elementary metals.
- The Parallelkinematic Module handles both the manufacturing and post-processing of intricate parts made from various alloys and metals within a single setup. This includes:
- Additive manufacturing
- Coating
- Reparation
- Post-processing and machining in the same setup
- Large-Area Production: Supports the fabrication of large-area components within a work envelope up to 3 x 2 meters in the Y x Z dimensions, with an extensive range in the X dimension, ensuring precise outcomes and near net-shape structures.
- Exceptional Dynamics: Achieves maximum accelerations of 2.5 G, significantly enhancing manufacturing speed and operational capabilities, especially for directional changes and contour fidelity.
- Microstructure Fabrication: Produces 3D microstructures with a minimum wall thickness of 500 μm and a surface roughness of approximately 20 μm.
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In addition, a more compact version of the PKM was designed in this way, to fit inside a standard 40-foot container, providing a workspace measuring 1.2×1.2×2.5 meters. This design facilitates easy transportation and supports additive manufacturing and machining operations within a single setup. It offers the versatility to handle both production and repairs, whether in-house or on-site. Additionally, an advanced calibration system quickly restores precision after transportation, maintaining consistent accuracy in any environment.
General information on 3DMD
In collaboration with Ponticon, we focussed on the so-called 3DMD process, which, in combination with the PKM, guarantees extremely fast and precise production rates. The workspace, which with the PKM is up to 4,000 x 3,000 x 2,000 mm and offers the possibility of 3- and 5-axis machining, opens up new dimensions for additive manufacturing.
Fast
The highly dynamic kinematics of the PKM machines enables surface rates up to 1,000 cm²/min and build rates up to 600 cm³/h.
Precise
Reproducible production of filigree 3D-structures with a minimum wall thickness of 500 μm and roughness of about 20 μm.
Flexible
Combination of diverse alloy systems and elementary metals with nozzle-based powder supply.
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