3D Metal Printing

Create complex metal products without moulds or welding

Vision


Helping Customers to navigate in a dynamic 3D-printing landscape

 

Entering the 3D printing world is a challenge. Several technical aspects need to be considered to find a feasible and competitive solution. Sagaz supports Customers through the downselection process.


Which design and material to choose? Will the achieved tolerances reach our demands? Sagaz helps Customers to evaluated essential qualifications to bring new or existing products into AM production.

About AM


Additive manufacturing


Additive manufacturing (AM) or 3D printing are terms to summarize various methods to built three-dimensional objects from eg a CAD model. One of the most common methods to print details in metal is Binder Jetting. This technology was founded in 1993 at Massachusetts Institute of Technology (MIT).

There are various suppliers on the market driving the technology development and lowering production costs. Some of these are mentioned in the table below.

Binder Jetting Technology


Cost efficient -  Impressing printing


Binder Jetting requires no support structure as the printed parts are surrounded by unused powder. Binder jetting printers are normally less costly than SLM due to absence of lasers.


The models above are a result of sintered metal powder. Patiently adding layer by layer the final shape is reached. As each layer is only 0.035 mm thick, it takes various hours to finalize a model.


Between the metal layers a carbon binder is applied. After adding all layers together the casing is brought to the oven where the powder is transformed into solid metal at more than 1100°C, close to the point of liquefaction.


When the model leaves the oven the size has shrunk 20%. After checking the measurements the surface could be treated to lower roughness before final polishing. Due to the model complexity surface polishing process needs to be done manually.

Why AM?


Shape new products and solutions "out of the box"


Introducing metal AM as an alternative to traditional mechanical production, is a long-term process. AM could be equated with a technical paradigm shift and it challenges established thoughts about product development and manufacturing. Drilling, milling, and turning are examples of processing methods which has been optimized for decades and hence very cost efficient. But although AM is a quite a new technology there are some obvious advantages which needs to be considered at every design department. 3D metal printing is a door opener to new and more efficient products which at the same time becomes cheaper to produce and faster to produce. Several industries have already introduced AM-produced products as standard and their ongoing investments are pushing the development forwards.  


In the example below the weight of the final product is reduced with 50% and at the same time the waste is minimized. More complex designs, normally produced through precision castings, could be shaped without expensive molds and inside cooling ducts.


Please get in contact to see how AM could improve your products, lower your manufacturing costs, and decrease the lead time.


Richard Nilsson, MSE Mechanical development, founder of Sagaz.

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