(powder) bed systems
e.g. Selective Laser Melting (SLM) or Selective Laser Sintering (SLS)
Additive Manufacturing
In Additive Manufacturing (AM) or 3D printing, components are produced by applying material layer by layer. For a production oriented design of the parts, a CAD software is needed. The components are printed using metal, polymer, ceramic, composites or hydrogels/bio inks as building material.
Additive layering methods
based on metal and plastic split up in
Benefits of AM
Comparison
Conventional vs. Additive Manufacturing
The Technology
Wire Arc Additive Manufacturing (WAAM)
Wire Arc Additive Manufacturing (WAAM)
- Layer-by-layer structure of the part using arc welding
- Fusing of a metal wire with the aid of a welding torch forms the blank
- Finishing of the fully built component by CNC-milling
Benefits
- Robust process
- Well-established and easy to handle
- High building rate
- Low residual stress in the component
- Qualified processes ensure the highest quality
Disadvantages of powder bed processes compared to WAAM
- Very sensitive process
- Much more complex to integrate in a mobile system
- Challenges in powder handling (Preparing and unpacking of the machine, work safety, …)
- Limited building space
- Complex post-processing
Patented Parallel Geometry
Multioptional 5-axis mobile machines from METROM
The Mobile Smart Factory uses a hybrid machine from METROM for component production. Based on a patented parallel kinematics concept the machine combines Gefertec’s WAAM module with a milling and drilling unit.
The automated building with integrated finishing processes is based on CAD data of the component created in the operating container. With this solution, the system operator only has to set up and position the workpiece. The welding and machining process runs as an NC program based on pre-qualified parameters.
Operating principle
The main spindle of the machine is centrally positioned, allowing the machining of large workpieces.
The measuring of the workpiece, contour welding and milling are carried out consecutively in one clamping position. Subsequently an additional tool can be used to smoothen out the roughness of the surface. All technological steps are realised by a direct tool change in the working area of the machine. Further possibilities like for example laser welding with wire or powder, screw extrusion additive manufacturing or plasma welding can be integrated later on, too.
Machine advantages at a glance
- Low weight and low power input
- Large building space with small installation area
- High positioning accuracy and repeatability
- Thermal compensation of the working envelope
- Stiffness without foundation works
- 3D-printing with integrated finishing
