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MetalFAB1 to Be First Metal 3D Printer with 3DSIM Print Simulation Software – ENGINEERING.com

by • April 13, 2016 • No Comments

At the form following in factt in Frankfurt last winter, the MetalFAB1 of Additive Industries created its big debut. But the machine was not physically present, attendees were treated to a virtual reality presentation of the huge and potentially game-changing metal 3D printing device. With may already astounding claims of “10x advantageous reproducibility, productivity and flexibility” in comparison to other metal 3D-printing technologies, the MetalFAB1 only succeded in another big boost to its performance as the initially industrial 3D printing device to incorporate initially-of-its-kind simulation software of 3DSIM.
The MetalFAB1 3D printing device of Additive Industries has a number of high end control and automation showcases created in. (Image courtesy of Additive Industries.)The MetalFAB1 3D printing device of Additive Industries has a number of high end control and automation showcases created in. (Image courtesy of Additive Industries.)
The MetalFAB1 system is equipped with automated create plate, product and powder handling, as well as multiple create chambers so that four various materials can be utilized inside a single machine, without cross-contamination or extended downtime for changing out metal powders. These showcases enable increased autonomy in the 3D printing device, but continuous in-system calibration and high end control may be in fact additional significant given the consistency issues related to metal 3D printing. On Apr. 5, at the Additive Manufacturing Users Group Conference, Additive Industries created an announcement that signals in fact greater high end assurance in the MetalFAB1 system through the use of 3DSIM’s exaSIM and FLEX software.
Automated create plate, product and powder handling allow for increased efficiency. (Image courtesy of Additive Industries.)Automated create plate, product and powder handling allow for increased efficiency. (Image courtesy of Additive Industries.)
Typically, in metal 3D printing, a laborious system of trial and error is performed with an additive making system until the user finds the precise parameters with that to print an object with consistent repeatability. Oftentimes, this limits the user to dedicate a machine to making with a single material, if not a specific object. GE has, for instance, built a 3D printing factory in Alabama with numerous systems devoted to the production of their LEAP jet engine nozzle. Because GE is a multibillion-dollar conglomerate, such an allocation of resources can be onlyified for this significant component, but the ends pretty don’t onlyify the means for smaller in size operations. More significantly, if metal 3D printing is at any time to complete widespread adoption, the high end control synonymous with traditional making techniques can require to be completed. In steps 3DSIM.
3DSIM is a University of Louisville spin off founded by Brent Stucker, whose work now serves as the basis for an high end suite of print preview programs for metal 3D printing. The cloud-based software uses existing data related to the interactions between energy, such as a laser beam (or four CO2 lasers in the case of the MetalFAB1), and materials, such as titanium powder, and simulates accurate meshes of 3D objects. This system may sound easy, but the physics synonymous with a heat source in a gas chamber turning solid dust into liquid metal is not easy. In fact, 3DSIM suggests that the mathematics required to manufacture such a prediction may take 5.7 x1018 years to solve on a 16-teraflop desktop. 3DSIM, howat any time, has managed to create a program that can do this work quickly via high end algorithms.
By inputting a 3D version into 3DSIM’s FLEX software, users can determine what can take place when the laser hits the dust and in fact sets of turning it into a solid. Whilst FLEX can determine the sort of porosity, part distortion and surface roughness an object can have, exaSIM is a separate program that generates optimized assist structures for a metal part to reduce material waste and ensure a proper print.
3DSIM is already open to beta testers for their software, but Additive Industries is now the initially company to manufacture use of this print simulation innovation. They have incorporated FLEX and exaSIM into their own Additive World platform, software createed for the MetalFAB1 3D printing device. As Additive Industries may already sold out of all of its beta machines in only three months this year, to customers as significant as Airbus, it may be of little surprise to hear that it can sell out of its following batch of production systems as well.
About the Author

Michael Molitch-Hou is a 3D printing specialist and the founder of The Reality™ Institute, a service institute dedicated to determining what’s real and what’s not so that you don’t have to. He is a graduate of the MFA significant studies and writing program at CalArts, and a firm advocate of world peace.

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