Metal Powder Gets Cheaper

Metal producer Metalysis has invented a much more efficient method to make fine metal powder. Currently the price of titanium powder ranges from USD$200-400 per kg as it is made through a complex multi-step process. Metalysis’ new process involves a single step and should reduce the price accordingly. 

 

While this is quite important for industrial metal 3D printer owners, there could be a connection to personal 3D printers as well. At the present there are no personal metal 3D printers available that use metal powder, but perhaps one of the reasons such a thing doesn’t exist is the prohibitively expensive cost of materials. 

 

Projects such as MetalicaRap could benefit from the availability of inexpensive powdered metal material. 

  

Via Metalysis

The Newton3D Metal 3D Printer

Personal 3D printers have a limitation: materials. Typically used with plastic, many people would like to 3D print in metal. Now there seems to be an option for personal metal 3D printing: the Newton3D, “built from the research of Esteban Schunemann, PhD student at Brunel University”. 

 

We don’t know very much about this mysterious device. There’s only a web page with a brief explanation, an extrusion video and a form to be put on the pre-order list. 

  

  

It seems that the Newton3D uses a two-step process: a metal clay is 3D printed using a standard extrusion approach, followed by a firing which presumably burns off the clay, leaving a metal object. The site claims a resolution of up to 0.4mm in a build volume of around 125 x 125 x 50mm. Not big - but it is metal. 

 

There’s no exhibition of finished metal objects, which is kind of critical to evaluate the technology. We’re hoping that the Newton3D proves out in the future, as there really aren’t any feasible metal solutions for personal usage. If the product works and is appropriately priced, it could open up a whole new world for personal printing. 

 

Via Newton3D

Solid Concepts’ Printed Metal Gun on Sale

In just short of two months 3D printing firm Solid Concepts has introduced, and will now sell a 3D printed metal gun.

 

While the model M1911 semi-automatic pistol is made from stainless steel and Inconel 625 it’s going to cost you a bit more than your standard issue US Army pistol.

 

According to Solid Concepts its 1911DMLS will run you $11,900, a figure that should buy you an entire arsenal not just a single weapon. However, for some firearms enthusiasts the 1911DLMS might be worth the money as Solid Concepts has stated it’s only planning to make 100 of the laser sintered pistols.

 

Read more at ENGINEERING.com

Design of the Week: Spider Table

This week’s selection is the “Spider” table created by UK designer Daneil Widrig, who produced this work as a private commission. It’s made from 3D printed titanium, using an SLM process, and a slab of glass. 

 

The table is quite large by 3D printing standards; it’s 2.05 x 1.0 x 0.73 meters, but just right for an incredible table in your home or office. 

 

We’re impressed with the transformation of the design’s startling complexity at the fine detail level into clear, curvy support structures holding up the glass sheet. While seemingly made from metal toothpicks, this structure is obviously strong enough to support a heavy piece of glass. 

 

Via Daniel Widrig

Miniature DMLS Prints Tiny Metal Parts

A joint venture between 3D-Micromac AG and EOS Gmbh has created a new micro-laser sintering technology (MLS) that can be used to create miniature metal components.

 

While the two firms have been developing MLS technology since 2006 under the name of 3D MicroPrint, it was only last year that the technology was mature enough the begin operations in a research setting.

 

According to Han J. Langer, CEO of EOS, “Demand for very small parts which are difficult to manufacture using conventional processes is rising tremendously. Micro Laser Sintering provides solutions for three major trends: individualization, functional integration, and miniaturization.”

 

Read more at ENGINEERING.com

A Personal 3D Metal Printer: In Progress

We're checking out a project that's listed on the RepRap Wiki: MetalicaRap. The goal is to produce a:

 

Open 3D metal & home solar cell printer, based on the principles of electron beam welding and vapor deposition.

 

No, it isn't ready yet - the project is still in the planning stages. While the primary objective of the project is to enable the inexpensive production of home solar cells, we're particularly interested in the ability to 3D print metal objects. 

 

The process to be used involves a powerful 300W electron gun firing into a vacuum chamber to melt metal powder. By repeatedly applying layers of metal powder and solidifying portions, metal objects are gradually built. 

 

The project's specifications are modest, considering the technological challenges it faces. In addition, this machine will be able to "largely" replicate itself, including the electron gun.  

 

This manufacturing process is unlike others attempted in the personal 3D printer space, generating unique challenges. For example, the 0.01mm metal powder is so small it can be affected by minor magnetic disturbances. Vacuum chambers are not required on typical personal 3D printers, but they will be required here. 

 

It's expected the MetalicaRap, when built, would cost thousands of dollars just for the components. 

 

The project has been open for over a year, but it appears they have lots yet to do. When MetalicaRap is finished it will be interesting to see how it changes the 3D printing community. Will we have 2.4m tall metal printers in our workshops? 

 

Via RepRap Wiki

Personal 3D Printing In Gold

Can you 3D print in gold at home? Not exactly. But we have found an example of how you can use 3D printing technology to cast gold. 

 

In a now-old post on the Ultimaker blog, jeweler Paul Steenbrink (a.k.a. Cardillac) experimented with a technique for preparing gold jewelry: 

 

The 3D print is invested in ceramic material and heated to +1500C and vaporizes, leaving a mould ready to cast from.

 

That's it! Put the 3D print (PLA) in a fluid ceramic and let it harden. Then simply burn out the plastic by raising the temperature sufficiently high. This leaves the ceramic with a void in the precise shape of the original 3D print. 

 

If you've designed the model with "sprues" that extend from the model, you can use them to pour liquid metal into the ceramic mold. 

 

Once the metal has cooled and solidified, crack open the ceramic to reveal your model in metal. 

 

And that metal could be gold, if you can afford to purchase the necessary materials.

 

Via Ultimaker

Open Source Metal 3D Printing

We ran across an interesting project that's attempting to create a system for 3D printing metal at very low cost. The idea is to do for metal manufacturing what was done for plastic manufacturing with current open source 3D printers. 

 

The project, by Andreas Bastian, is entitled "An Open Source Selective Laser Sintering 3D Printer for Rapid Manufacturing in Wax". And that gives you a strong clue on how the process works.  

 

The "SLS" device does not actually 3D print in metal, because that would require very expensive mechanics and large quantities of electricity. However, the project accomplishes its objective by actually 3D printing in wax. 

 

But wax isn't metal! No worries - simply use the 3D printed wax shape in a "lost wax process" to convert it into metal. The wax print is placed in a tub of plaster. By pouring in hot liquid metal, the wax burns away and molds to the shape of the plaster. Crack away the plaster and you've got yourself a piece of metal in exactly the same shape as the original wax item. 

 

While this approach is inexpensive, it does have some limitations when compared to true metal 3D printing: 

 

• The wax pieces and subsequent plaster molds can be used only once to produce one metal piece
• The geometry of the shape must be "moldable"; items with hidden interior material can't be made with this process

 

Nevertheless, it's good to see experiments in personal metal 3D printing emerging. 

 

Via Andreas Bastian

ESA's Launch into Metal 3D Printing

The European Space Agency has launched an initiative to develop complex metal 3D printing techniques for space missions. The Amaze initiative (standing for "Additive Manufacturing Aiming Towards Zero Waste and Efficient Production of High-Tech Metal Products", somehow) brings together 28 different organizations that have a stake in the process, either by research (Universities) or industry (AirBus, for example). 

 

For ESA the results could be spectacular. By 3D printing an entire satellite in one single piece, they could significantly reduce the mission's weight. How? When multiple pieces are used, you must provide bolts and nuts to hold them together - plus reinforced holes to hold those bolts and nuts. All that adds up to a lot more weight - and size in some cases, too. 

 

The benefit, they say, is a reduction in cost by half, and that's a big deal when your space expeditions cost millions. 

 

The spin offs for the rest of us will be more efficient airplanes, reactors, vehicles. 

 

And maybe a ticket to space we can actually afford. 

 

Via BBC

Your Rocket Is Now 3D Printed

Aerojet Rocketdyne has been working with NASA to develop a way to 3D print rockets. Well, not the WHOLE rocket, but certain critical parts, namely an Injector Assembly. 

 

They're working on a completely integrated manufacturing process  with Selective Laser Melting technology that will be capable of rapidly producing "highly critical rocket engine components". We suspect they are leveraging 3D printing's ability to create complex objects that are lightweight compared to the traditional method of bolting several pieces together - which often adds significant weight. 

 

The twist here is that they have to certify that the parts produced are truly safe to use by passing numerous tests. Part of that certification was accomplished recently by using a 3D printed part in a "hot fire test". You can imagine what that means.  

 

The test was successful; More rocket parts will be printed. 

 

Via Rocket

Optomec’s Mini Metal Printer

In the world of 3D printing, bigger really is better,  but New Mexico-based Optomec plans to take things in a different direction.  The company will bring selective laser sintering down to the micro scale with their new Laser Engineered Net Shaping printer.

 

Originally created at Sandia National Labs for use by the military and aerospace industry, the LENS 450 printer has just a 100x100x100mm (3.94x3.94x3.94in) build volume, and constructs parts mainly from titanium, stainless steel, cobalt, chrome, and superalloys. With those restrictions, you wouldn’t expect to get much out of it, but it’s still starting to catch the eye of several industries.

 

Read More at ENGINEERING.com

3D Systems Acquires Phenix Systems

3D Systems continues its acquisition run with the announcement they've agreed to take on Phenix Systems, a manufacturer of metal 3D printing devices. 

 

France-based Phenix Systems uses the "Direct Metal Selective Laser Sintering" process, which uses high-powered lasers to fuse layers of metal powder into solid objects at very fine resolutions. The process is very similar in concept to 3D Systems' SLS process, but uses metal instead. 

 

3D Systems has not yet bought the 13-year old Phenix outright; instead they've "only" acquired some 80% of Phenix's shares. However, they intend to pursue the remaining 20% after the main acquisition deal closes in July, with the goal of a clean 100% ownership. 

 

3D Systems' strategy is to offer as many different 3D printing processes as possible, as they (correctly) believe that no single process can serve all needs. With this acquisition, they've added a key capability to their already daunting arsenal of 3D printing processes. 

 

Via 3D Systems

GE's Making 3D Printed Jets

The prestigious MIT Technology Review has named General Electric's work on 3D printing as one of its "10 Breakthrough Technologies 2013". 

 

Specifically, GE is developing a metal nozzle for its LEAP jet engine. They will use 3D metal printers to produce the nozzles, which will be lighter in weight due to an advanced design producible only on 3D printers. 

 

Wait, we've heard this story many times before. A company improves their business process by involving 3D printing. What's the big deal? 

 

The big deal here is the volume. GE is MASS PRODUCING these nozzles with 3D printing. They are not producing mere prototypes. Even more importantly, this is a critical piece of the engine of an aircraft, something you don't fool around with. This indicates the serious capability of 3D metal printing technology. 

 

While we say it's mass produced, there is a caveat: Each engine requires some 10 to 20 nozzles, and there only so many engines on order. In total GE will require some 25,000 nozzles. That sounds like a lot, but it's far fewer pieces than say a one million piece mass production order. So yes, they are mass produced for an industry that requires "small run" mass production. 

 

A 3D printing milestone nevertheless.  

 

Via MIT Technology Review

UMT Develops 3D Printing Metal Smoothing Technology

We had a brief encounter with Alexander Lobovsky, P.E., who is a partner with United Materials Technologies of New Jersey. Lobovsky's company is developing a new method for smoothing 3D metal prints. 

 

The problem with metal 3D prints is the same as plastic: printing by layer causes visible ridges on the object. These can be larger or smaller depending on the technology, but are always present. Metal parts are particularly vulnerable as people are used to seeing (and touching) smoothly casted/forged/cut pieces.  

 

Lobovsky's technology somehow manages to smooth out these ridges successfully, as you can see in the image above.  

 

The most common method of smoothing parts, both plastic and metal, is simply to toss them in a tumbler containing an appropriate abrasive and they'll smooth out. However, this approach doesn't work for all objects. We believe Lobovsky's technology may be able to address many more geometries. 

 

Via United Materials Technologies