MBDM@Additive specializes in the Design of Prototype Parts for Additive Manufacturing (AM). Our AM process offerings are recognized by the American Society for Testing and Materials (ASTM), and includes over 100 different materials along with the few shown below:
Carbon Fiber Based Melting - Reinforced (CBFM)
ABS Carbon - Carbon Fiber Reinforced (ABS)
Pro PLA High Tensile High Impact Strength (PPLA)
FormFutura - MetalFil - Powder Fusion
Proto-Pasta - Brass Filled Metal Reinforced
Our process creates a physical object from a digital design or CAD file. In all of MBDM@Additive’s smelting machines, the processes involve the spreading of the metal powder layer by layer and uses either a laser or electron beam to melt and fuse powder together to create a part. The process repeats until the entire part is created. Loose or unfused powder is removed during post processing and is recycled for the next build.
Additive manufacturing, also known as 3D printing, is a process that creates a physical object from a digital design.
Additive manufacturing materials
It is possible to use many different materials to create 3D-printed objects. AM technology fabricates jet engine parts from advanced metal alloys, and it also creates chocolate treats and other food items.
Thermoplastic polymers remain the most popular class of additive manufacturing materials. Acrylonitrile butadiene styrene (ABS), polylactic acid (PLA) and polycarbonate (PC) each offer distinct advantages in different applications. Water-soluble polyvinyl alcohol (PVA) is typically used to create temporary support structures, which are later dissolved away.
Many different metals and metal alloys are used in additive manufacturing, from precious metals like gold and silver to strategic metals like stainless steel and titanium.
A variety of ceramics have also been used in additive manufacturing, including zirconia, alumina and tricalcium phosphate. Also, alternate layers of powdered glass and adhesive are baked together to create entirely new classes of glass products.
Biochemical healthcare applications include the use of hardened material from silicon, calcium phosphate and zinc to support bone structures as new bone growth occurs. Researchers are also exploring the use of bio-inks fabricated from stem cells to form everything from blood vessels to bladders and beyond.
Additive Manufacturing Advantages
Additive manufacturing allows the creation of lighter, more complex designs that are too difficult or too expensive to build using traditional dies, molds, milling and machining.
AM also excels at rapid prototyping. Since the digital-to-digital process eliminates traditional intermediate steps, it is possible to make alterations on the run. When compared to the relative tedium of traditional prototyping, AM offers a more dynamic, design-driven process.
Whether additive manufacturing is used for prototyping or production, lead times are frequently reduced. Lead times for certain jet engine parts have been reduced by a year or more. Also, parts once created from multiple assembled pieces are now fabricated as a single, assembly-free object.
In designing everything from bridges to skyscrapers, engineers have long sought to minimize weight while maximizing strength.
With additive manufacturing, designers realize the dream of utilizing organic structures to greatly reduce the weight of obje
AM excels at producing parts with weight-saving, complex geometric designs. Therefore, it is often the perfect solution for creating light, strong aerospace parts.
In August 2013, NASA successfully tested an SLM-printed rocket injector during a hot fire test that generated 20,000 pounds of thrust. In 2015, the FAA cleared the first 3D-printed part for use in a commercial jet engine. CFM's LEAP engine features 19 3D-printed fuel nozzles. At the 2017 Paris Air Show, FAA-certified, Boeing 787 structural parts fabricated from titanium wire were displayed, according to Aviation Week.
Our Creaform MetraSCAN
750 Elite 3D Scanner with
Handyprobe Next System
The Metrascan 750 is one of the
most highly accurate 3D scanners
in production and provides a
metrology grade 3D Mesh or point
cloud which can be used for reverse
engineering and first article inspection. Metrascan and
Handyprobe comes with VX Element 8.1.2. The Scanner and Probe works great with almost all Inspection software like Polyworks.
It Allows Us to Produce UltraSCAN 750 Elite Specifications:
WEIGHT: 0.5 kg (1.1 lbs.)
ACCURACY: Up to 0.020 mm (0.0008 in.)
VOLUMETRIC ACCURACY: 9.1 m3 (320 ft3) 0.064 mm (0.0025 in.)
MEASUREMENT RATE: 480,000 measurements/s
SCANNING AREA:275 x 250 mm (10.8 x 9.8 in.)
Sintering is the process of creating a solid mass using heat without liquefying it. Sintering is similar to traditional 2D photocopying, where toner is selectively melted to form an image on paper.
Direct Metal Laser Sintering (DMLS)
Within DMLS, a laser sinters each layer of metal powder so that the metal particles adhere to one another. DMLS machines produce high-resolution objects with desirable surface features and required mechanical properties. With SLS, a laser sinters thermoplastic powders to cause particles to adhere to one another.
By contrast, materials are fully melted in the DMLM and EBM processes. With DMLM, a laser completely melts each layer of metal powder while EBM uses high-power electron beams to melt the metal powder. Both technologies are ideal for manufacturing dense, non-porous objects.
Stereolithography (SLA) uses photopolymerization to print ceramic objects. The process employs a UV laser selectively fired into a vat of photopolymer resin. The UV-curable resins produce torque-resistant parts that can withstand extreme temperatures.
Additive manufacturing applications
Additive manufacturing is already used to produce an impressive array of products -- everything from food creations to jet engine parts.
At the NYU School of Medicine, a clinical study of 300 patients will evaluate the efficacy of patient-specific, multi-colored kidney cancer models using additive manufacturing. The study will examine whether such models effectively assist surgeons with pre-operative assessments and guidance during operations.
Global medical device manufacturing company Stryker are funding a research project in Australia that will use additive manufacturing technology to create custom, on-demand 3D printed surgical implants for patients suffering from bone cancer.
In general, healthcare applications for additive manufacturing are expanding, particularly as the safety and efficacy of AM-built medical devices is established. The fabrication of one-of-a-kind synthetic organs also shows promise.
CNN reported that the McLaren racing team is using 3D-printed parts in its Formula 1 race cars. A rear wing replacement took about 10 days to produce instead of five weeks. The team has already produced more than 50 different parts using additive manufacturing. In the auto industry, AM's rapid prototyping potential garners serious interest as production parts are appearing. For example, aluminum alloys are used to produce exhaust pipes and pump parts, and polymers are used to produce bumpers.