Development times reduced
October 1st 2010

The process of Additive Layer Manufacturing (ALM) offers benefits for direct part production, says ES Technology, Republic of Ireland distributor for Concept Laser's Additive Manufacturing systems

Additive layer manufacturing for direct part production continues to grow and is fast becoming a significant part of the overall ALM industry. The many benefits of this process have seen the technology embraced by a number of manufacturing sectors including the automotive industry, where the technology is already being used, for not only rapid prototyping, but pilot production and small series production of engine and other mechanical components.

The company believes that the ability to produce components in a wide range of materials including steel, titanium and aluminium alloys, presents industry with immense potential for direct part production using ALM.

Concept Laser is part of the Hofmann Innovation Group, based in Lichtenfels, Bavaria. An expert in the field of generative metal laser fusing with its LaserCUSING technology, it has installed more than 100 systems. The company believes the LaserCUSING process can provide benefits to automotive and motor sport companies when developing new components.

The 'Tool-Less' principle of manufacturing components means that within only a few days (manufacturing 24h/day), components can be produced using original materials with corresponding material characteristics.

The relatively short timescales involved in producing parts means rapid integration of the component into a test vehicle, helping to reduce development times.

LaserCUSING has been used to manufacture components such as racing exhaust manifolds. Produced on a Concept Laser M2 cusing machine from CL 31AL (AlSi 10Mg), using a 200W fiber laser system, the component was able to be directly fitted to the test vehicle upon completion.

Additional automotive components produced using LaserCUSING include a steel engine manifold, aluminium pump housing and aluminium door handle mounting. Other automotive components produced using this technology include oil pump housings, wheel suspension components and thin 'sheet metal' style parts which were used in the development of a prototype vehicle. In each case the parts were produced direct from CAD using 3D/CAD-design software systems such as CATIA/ Pro-Engineer and AutoCAD.

Concept Laser has also developed a range of materials for use with the LaserCUSING process, and suited to the production of automotive components, including:

CL 20ES (1.4404)/ stainless steel: Stainless steel for technical prototypes and small series production CL 31Al (AlSi10Mg)/ aluminium alloy, low in weight and suitable for technical prototypes and small series production CL 40Ti (TiAl6V4)/ titanium alloy Titanium alloy for lightweight components in racing. Suitable for technical prototypes and small series production Concept Laser has developed a Quality Management System for use with its LaserCUSING Systems. Features include real-time inspection of the melt pool, online laser and performance monitoring, software modules for analysis and report generation following the build process, redundant monitoring and control of the oxygen concentration in the process gas atmosphere and analysis of the powder quality, together with good preservation of the powder quality using an external and fully automatic sieving station.

ES Technology is the Republic of Ireland and United Kingdom distributor for Concept Laser's Additive Manufacturing systems and is responsible for the sales, marketing and support of Concept Laser's systems within these territories.