Metal Additive Manufacturing Laboratory
The Metal Additive Manufacturing Laboratory focuses on the research and development of metal additive manufacturing (3D printing) technology and advanced applications which enable the production of previously unmanufacturable metal parts or specially optimized and complex parts for the aerospace or automotive industries. In addition to special and prototype parts, we also produce modern cutting tools using additive and conventional technology. We not only design these tools, but also measure and modify key design elements such as cooling systems, geometry and microgeometry in detail. We can modify the surfaces of additively manufactured pieces, cutting tools or other complex surfaces by grinding or polishing and then comprehensively analyse and evaluate them using modern diagnostic equipment.
ADDITIVE MANUFACTURING OF METAL PARTS
The laboratory specializes in research into additive manufacturing processes and their uses in the process of sequential melting of metal powder layers by laser beam (DMLS) to create a homogeneous 3D object with the desired properties. In this way we can produce prototype pieces as well as complex shaped parts and structures that cannot be produced by any other technology.
A special in-situ monitoring system which records the progress of laser melting in individual layers is used to monitor and analyse the processes taking place inside the printed pieces and their influence on the final quality and properties of the additively manufactured parts. The laboratory is also equipped with other advanced equipment not only for additive manufacturing but also for subsequent finishing operations. This enables the laboratory to produce parts up to 250 × 250 × 325 mm from MS1 tool steel, 316L stainless steel, special nickel alloy Inconel 718 and HX.
PREPARATION AND OPTIMIZATION OF PRINT MODELS
Well-prepared print models and the set-up of the printing process are essential for achieving optimal flow and productivity in additive manufacturing and to ensure the desired properties of the parts. Our laboratory is equipped to provide complete design and technological preparation for additive manufacturing, which includes the construction and optimization of 3D models, validation and modification of clients’ models, topological optimization or weight-reduction of components using special internal grid structures, creation of the necessary support structures, appropriate spatial orientation of parts on the printing platform, setting up effective process parameters and test simulations of the additive manufacturing process.
DESIGN AND MANUFACTURE OF CUTTING TOOLS
The second specialization at our laboratory is the design and production of standard and special solid cutting tools made of various cutting materials (RO, SK, Cermet) and the optimization of cutting tools with replaceable cutting inserts. We use state-of-the-art software for precise calculation of groove and grinding wheel shapes, stress analysis and grinding simulations, etc. Some of these tools can be manufactured using additive manufacturing technology, where the main benefits include the optimization of the tool shape and cooling system.
MICROGEOMETRY MODIFICATION AND SURFACE POLISHING
No production tool today can do without cutting edge modification. Therefore, we have long dealt with cutting processes and their influence on tool durability and the quality of the machined surface. We can also carry out the necessary adjustments to the polishing of groove surfaces, which increases a tool's usability. We can also apply this polishing technology to general shapes where the resulting surface roughness is can be lower than Ra 0.02 μm.
MEASURING SURFACE ROUGHNESS AND MICROGEOMETRY OF CUTTING EDGES
In many cases, it is not enough to evaluate a surface by profile roughness alone, which cannot evaluate the whole surface. In our laboratory, we have long-term experience with surface parameter evaluation and are able to measure and evaluate surface roughness using the volumetric parameters of the surface. We are also involved in the evaluation of tool microgeometry, particularly the radius of curvature of the blade, K factor, face and back surface roughness of the wear surface.
LABORATORY EQUIPMENT
EOS M290 3D printers
The laboratory is equipped with two EOS M290 printers, which work on the principle of DMLS (Direct Metal Laser Sintering) technology. The objects printed by this technology are created in thin layers that are sequentially fused at certain points by a laser beam. This enables the creation of parts with any external and, above all, internal shapes that cannot be produced by any other conventional method. The progress of the additive manufacturing process can be monitored using a special in-situ monitoring system, which detects any hidden internal defects in the printed parts and identifies critical points, leading to subsequent optimisation and streamlining of the entire additive manufacturing process. For the production of metal parts, the laboratory uses MS1 tool steel, 316L stainless steel, Inconel 718 special alloy and HX.
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 are clear and illustrative reports.
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.
