Page 9 - 3D Metal Printing Winter 2020

By Mark Barfoot
AM INSIGHTS 3D Five Steps for Getting Started
Introduction to AM:
At the start of a
new year, many manufacturers
find themselves considering
new technologies and tech-
niques. Increasingly, these
include additive manufacturing (AM). But where to begin? This article will walk you through five steps for navigating metal 3D printing.
No. 1: Explore
As you begin your metal 3D
printing quest, explore the many solu- tions out there, each with its own strengths, and each represented by multi- ple companies. This can be confusing as vendors market the benefits of their sys- tems and, in many cases, label similar technologies differently. One technology may be great for one company, but not for another, depending on the application. Example: wire-based directed energy deposition (wire-DED) versus laser pow- der bed fusion system (L-PBF). DED builds large, near net shape parts quickly, to 25kg/hr, but has large layer lines, which typically require post machining afterward. An L-PBF system, however, excels at finely detailed small parts, but often requires long build times, which can be cost-prohibitive as parts get larger.
Mark Barfoot (mbarfoot@ewi.org), as director of additive manufacturing (AM) programs for EWI, oversees AM initiatives and helps develop new AM technology opportunities. He also directs the Additive Manufacturing Consortium, a national consortium of industry, government, academic and non-profit research organizations operated by EWI; manages EWI’s interest in ASTM International’s AM Center of Excellence, focused on AM standards development, projects, education and training; and remains an active member of the Additive Manufacturing Users Group after having served as president of the group.
Wire-DED part with large layer
lines
No. 2: Invest Time
Many companies expect to put an AM machine
into their facility one day and build production parts the next. This rarely happens,
because of the learning curve. Expect to invest 6 to
12 months before becoming fully knowledgeable on the
system as you will need to learn how to adjust the program settings for your specific material, geometry and
machine; how to utilize support struc- tures to hold the parts while building; and steps for ensuring proper heat transfer and cooling. Be sure to account for this learning curve in your ROI calculations.
No. 3: Don’t Assume Part Conversion
Converting an existing CNC- machined part design to additive typical- ly will not be cost-effective or practical. Metal 3D printing is most successful for parts designed specifically with features and geometries that cannot be made with traditional manufacturing. In addi- tion, the technology often enables the combination of multiple parts into a sin- gle piece, which can eliminate assembly time, reduce weight from mounting hardware and result in an optimized part.
No. 4: Don’t Assume Installation Without Modifications
Most metal 3D printing systems require some level of facility/safety pre- cautions. Many metal systems deal with powder, and thus require specialized air conditioning/humidity control to ensure that the powder does not deteriorate or
change its performance over time. Pow- der handling typically requires personal protective equipment, such as respira- tors, gloves and overalls, to ensure oper- ator safety. Powder also can be a fire and explosion hazard if not handled proper- ly and may require proper storage and fire suppression systems. In some cases, these requirements cost as much, if not more, than the machine, depending on local building codes. Make sure you find out what is required.
No. 5: Consider Outsourcing
Whether it makes sense to bring the technology inhouse or work with exist- ing service bureaus that have the machines, expertise and ability to pro- duce your parts is not a simple decision. However, I recommend outsourcing ini- tial trial parts. This provides an opportu- nity to validate parts without being fully invested and knowledgeable on the equipment and process.
Persistence Pays
Above all else, do not get discour- aged; there is a lot to learn. I have been in the AM world for nearly 20 years, and I still struggle to keep up with the nuances of the various processes and the rapid pace of innovation.
Remember, you do not have to do it on your own. Events such as AMUG, RAPID/TCT, formnext and 3DMP’s 3D Metal Printing and Tech Tour connect attendees with technologies and industry experts. EWI’s Additive Manufacturing Consortium provides another education- al and networking opportunity. Other organizations such as America Makes and ASTM International offer industry events. Metal 3D printing can be chal- lenging, but it also offers huge benefits. So let’s get started. 3DMP
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WINTER 2020 • 3D METAL PRINTING | 7