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Additive Manufacturing

Metal Laser Melting - Additive Manufacturing

How Imagination and Metal Powder Create Groundbreaking Solutions

Structures that seemed previously impossible. Efficient cooling of entire geometries in confined space. Just two examples of how 3D metal printing opens completely new dimensions of thinking and working.

With additive manufacturing, we have set out stakes on innovation once again. And combined with our proven core competencies we deliver significant added value. Layer by layer, high-performance metal powders are melted and precision shaped by means of a laser. Depending on the requirements we process aluminium alloys, nickel-based alloys such as Inconel® 625 and many others. In a subsequent machining process, the structures are finished to functional components. A truly pioneering achievement by toolcraft – and precisely the total solution demanded by many markets.

The benefits of the generative production method are evident: Even highly complex geometries can be realised – without any tooling, with considerable time savings and less material wastage. The resulting quality is convincing, and metal laser melting meets even the high requirements in aerospace and motor sports. Since 2018 the process is in accordance with Nadcap certification.

However, the quality and surface finish of components is pivotal, especially in applications where ensuring safety and gaining certifications is important. This is why in addition to analysing the powder used, toolcraft evaluates the properties of additively manufactured test pieces, as these are representative of the subsequently produced components. We are now testing the dynamic strength of various metals using fatigue testing. The resulting Wöhler curves indicate the relationship between the number of cycles to failure and the applied stress.

Complete process chain in 3D metal printing with Siemens NX

The technology "additive manufacturing" at a glance

    • Benefits
    • Materials

    Convincing: How You as Our Customer Can Take Advantage of Metal Laser Melting

    • Greater freedom of design.
      Even the most complex geometries are possible.
    • Broader range of applications.
      Also suitable for materials that are hard to machine.
    • Clear time and resource savings.
      Parts manufactured within a few days, no need for tooling.
    • Profitability.
      Lower part costs, less warpage and/or formation of voids.
    • Innovation potential.
      As your partner in research and development, we open new perspectives and market opportunities for you.
    • Optimal price-performance ratio.
      With us, you can realise prototypes, pilot and small series quickly and cost-efficiently. Thereby the main factors are the exposure and coating time.

    Versatile Material Base

    Mechanical strength, heat resistance, bio-compatibility, ...: When selecting the right material for laser sintering, we match our material and manufacturing expertise to your requirements. Metals we currently process include:

    • Aluminium alloys, such as AlSi10Mg, Scalmalloy®
    • Titanium alloys, such as TiAl6V4
    • Nickel-based alloys, such as Inconel® 718, Inconel® 625, Haynes® 282
    • Tool steels and stainless heat-resistant steels, such as 1.4828, 1.2709
    • Iron-nickel alloys, such as 1.3912 (Invar)

    Impressions of our Metal Laser Melting dimension

    • Metal laser melting center
      Metal laser melting center
    • Suction of powder at metal laser melting
      Suction of powder at metal laser melting
    • Continuous process chain with Siemens NX
      Continuous process chain with Siemens NX
    • Processing chamber
      Processing chamber
    • Vane
      Vane
    • Fatigue testing
      Fatigue testing
    • Burner
      Burner
    • TruPrint 3000 from TRUMPF
      TruPrint 3000 metal laser machines from TRUMPF
    • metal powder
      High-quality metal powder
    • Cooling jacket internally cooled medical technology
      Cooling jacket
    • Vacuum furnace
      Vacuum furnace
    • 3D printed pin
      Internally cooled mould inserts
    • Swirler, HDV turbine blade and IKZ tool holder recess turning
      Swirler, HDV turbine blade and IKZ tool holder recess turning
    • Tensile specimen
      Tensile specimen
    • Metal laser melting laboratory
      Metal laser melting laboratory
    • Sieve cell
      Sieve cell