Report

Teaser, summary, work performed and final results

Periodic Reporting for period 1 - Aerosint (Reinventing 3D printing into a true multi-material process)

Teaser

Laser powder bed fusion is an industrial additive manufacturing (AM) process in which a directed laser consolidates powdered material layer by layer into useful metal or polymer parts. LPBF techniques are currently limited to processing single materials because of the lack of...

Summary

Laser powder bed fusion is an industrial additive manufacturing (AM) process in which a directed laser consolidates powdered material layer by layer into useful metal or polymer parts. LPBF techniques are currently limited to processing single materials because of the lack of innovation in the powder deposition process. Aerosint’s technology is a selective powder deposition system that, when integrated into a LPBF process, could theoretically make the process capable of producing parts from multiple materials and drastically reduce material waste.

Multi-material AM is important for society because it could represent a revolution in manufacturing. 3D printing / AM permit the fabrication of parts with optimized geometries that are inaccessible with traditional manufacturing techniques like machining and casting. With multi-material AM, both geometry and material distribution could be optimized for the unique function of the part. Such optimization leads to parts which are lighter, stronger, make more efficient use of raw materials, and which have numerous impactful applications in medicine, energy generation and storage, and aerospace. Significant reduction of polymer material waste is also possible, as Aerosint’s system allows the use of separate, non-fusing support materials that do not

The overall objectives of the market validation and technical feasibility study were to identify market segments in which multi-material AM would bring the greatest value, verify our assumptions about these opportunities through conversations with market players, and verify on a basic level that multi-material processing using Aerosint’s technology can be achieved. Through conversations with major market players we conclude that the market opportunity for both multi-material and powder savings applications is high. Our preliminary tests of multi-polymer part creation and multi-metal co-fusion indicate that the technical barriers are low enough to justify continuing the project and bringing a multi-powder deposition system to market.

Work performed

Aerosint completed the SME instrument Phase I study in order to validate the market interest and initial technical feasibility of its selective powder deposition system for enabling waste-free or multi-material AM. Having already demonstrated that two separate powder materials could be co-deposited in a single layer, the next technical step to demonstrate feasibility was to test material co-consolidation after powder deposition in a relevant machine environment. We showed that co-sintering of polymers of different colors and rigidities is possible at a basic level. For metals, we collaborated with the Fraunhofer IGCV research institute, which has demonstrated previous success in co-processing of steel and copper alloy in a single part. There is thus a very high chance that metals deposited with Aerosint’s system can be fully co-consolidated into a single part. Work is also under way at Aerosint to demonstrate binder-free and waste-free ceramic, multi-ceramic, and ceramic-metal part fabrication.

Through market research and direct conversations with potential end users, we have validated the market opportunity for selective powder deposition as applied to AM. The research indicates that the additive manufacturing market is growing quickly with a current estimated growth rate of 12.5% per year. Companies using AM are increasingly interested in metal materials and using AM methods for small series production in addition to prototyping. The clear goal is accelerated product development leading manufacturing. We have validated that material waste cost in industrial polymer AM is a large pain point for service bureaus, and it inhibits the processing of high performance polymers. Multi-material AM is currently an almost non-existent market, but conversations with industry players indicate real interest for multi-material parts, especially in sectors like aerospace, soft robotics, and medical prostheses.

Our findings justify further development of selective powder deposition technology, both for material savings and multi-material applications. In the short term these developments will be made in cooperation with research centers and other SMEs with specific need for Aerosint’s technology. In the longer term, our go-to-market strategy will likely involve co-development with a major OEM of LPBF system to leverage their machine-building expertise and existing sales and distribution channels.

Final results

In this project we demonstrated, to our knowledge, the first commercial example of the feasibility of multi-material polymer LPBF using a selective powder deposition system. We also successfully integrated and tested the first selective powder deposition system integrated into a metal LPBF system, in cooperation with the Fraunhofer IGCV. This work supported in part by the European Commission will serve to aid Aerosint in its growth and commercialization activities, thereby benefiting employment and the economy in the Meuse-Rhine region. More broadly, the Aerosint project’s success will help strengthen Europe’s leadership in manufacturing innovation worldwide.

Website & more info

More info: http://www.aerosint.com.