Metal Additive Manufacturing Laboratory
The laboratory focuses on research and development in metal additive manufacturing based on the selective laser melting (SLM) principle. A homogeneous 3D object with the required properties is created by gradually melting added metal powder layers with a laser beam. In this way, we prepare prototypes as well as a series of components with high added value in the form of internal and external shape complexity and material saving while preserving the required mechanical properties and working characteristics. Our laboratory is exceptional thanks to special equipment, such as an in-situ monitoring system of the manufacturing process, which provides important real-time information on the melting process in individual printing layers and potentially critical points of the manufactured components. Equally important is our know-how, which we have intensively developed over the last 10 years.
Metal additive manufacturing (3D printing)
In the field of metal 3D printing, we provide:
- design and technological preparation
- topological optimization
- optimization of parts using lattice structures
- development of printing process parameters for a specific application
- simulation of the printing process
- in-situ process monitoring - non-destructive quality control of printed components
- custom additive manufacturing, including required heat treatment and surface treatments
- relevant post-processing
Materials used for additive manufacturing
- Martensitic steel MS1 (W-No. 1.2709)
- Stainless steel 316L
- Nickel alloy Inconel 718
- Nickel alloy HX
- Soft-magnetic alloy FeSi3
Research and development
We have been engaged in research and development activities in the field of additive manufacturing for more than 10 years. We have experience in submitting and solving national and international projects in diverse project calls. Our research is focused on the area of material and mechanical properties of additively manufactured components achieved as a result of changing process parameters. The development of process parameters aims to eliminate undesirable phenomena of additive manufacturing, such as minimizing structural inhomogeneities, residual stresses, and post-printing roughness, and also to link with other advanced manufacturing methods, such as hot spraying or other additive manufacturing technologies. In current projects, we use artificial intelligence tools to predict the functional properties of additively manufactured components. We apply our research and development results to specific orders, taking great care to be discreet and loyal to our industrial partners.
Cutting tool design and manufacturing
Another important specialization of the laboratory is the design and production of standard and special monolithic cutting tools made of various cutting materials (RO, SK, Cermet) and the optimization of cutting tools with replaceable cutting inserts. For this purpose, we use state-of-the-art software, supporting, e.g., precise calculation of groove and grinding wheel shapes, stress analysis, or grinding simulation.
We also manufacture customized tools using additive technology, where we take advantage of its benefits such as weight reduction, optimized shapes of cooling channels, i.e., supply to the required locations, and effective cooling intensity even on conventional machinery.
Surface finishing and modification of the defined radius of curvature are carried out by drag plastering technology. Of course, the geometry and micro-geometry of the tool are controlled.
LABORATORY EQUIPMENT
EOS M290 3D printers
The laboratory is equipped with two EOS M290 printers with a working space of 250 × 250 × 325 mm, and in-situ monitoring systems OT (Optical Tomography), MP (Melt Pool), PB (Powder Bed), which allow us to detect any hidden internal defects and identify critical areas of the product. We can optimize and improve the additive manufacturing process by modifying relevant processing parameters based on the results.
Alicona Infinite Focus Metrology G4 optical scanning microscope
The IFM G4 microscope enables the capture of surface topography, including its true colour. Its main advantage is the integrated measurement of shape and roughness in both 2D and 3D, thus combining the functionality of several similar measuring devices. The output of the measurements is a clear and illustrative report.
OTEC DF 3 surface preparation equipment
This tool for surface and cutting-edge dressing, including helical groove polishing, uses drag dressing technology. The tool or workpiece is clamped in a rotating head that is gradually submerged into a medium that applies pressure to the surface, resulting in the desired finish. The advantage of this device is also the possibility of tilting the head, which makes it possible to polish tool grooves. The device can also be used for finishing 3D-printed parts.
ANCA MX7 tool grinder
This machine is designed for grinding solid tools with a minimum diameter of 0.5 mm. It is equipped with high-precision spindles and other accessories to enable grinding within the prescribed tolerances. It can also be used to grind interchangeable inserts and free profiles from various machined materials, including aluminium and titanium alloys. The laboratory also has the necessary supporting software and production control equipment.
