Additive Manufacturing

Powder bed and powder nozzle: How imagination and metal powder create groundbreaking solutions

Process chain
Benefits and facts
Case studies
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Structures that seemed previously impossible. Efficient cooling of entire geometries in confined space. Just two examples of how additive manufacturing opens completely new dimensions of thinking and working.

Technology.

In laser powder bed fusion (L-PBF), lasers are used to melt down high-performance metal powders layer by layer, before shaping them into the desired form. In laser material deposition (LMD), on the other hand, a powder nozzle and lasers are used to deposit the material precisely on to the tool. We perform this process using a bespoke Trumpf TruLaser Cell 3000 with a horizontal and vertical rotary axis. We then use machining processes to refine the unmachined parts, turning them into complete functional components.

Application.

Additive manufacturing enables the production of highly complex geometries without the need for any tools – much more quickly and with fewer resources than traditional production methods. And the high-quality results speak for themselves. We can even fulfil the stringent requirements of the aerospace and motorsports industries. We have been Nadcap and TÜV Süd certified since 2018. Using the powder nozzle, we can repair defective components, apply coatings and wear protection, and produce hybrid structures. Our nozzle technology and our machinery’s design also allow us to perform extreme high-speed laser material deposition (EHLA), which is a process developed by the Fraunhofer Institute for Laser Technology ILT.

Quality assurance.

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. The dynamic strength of various metals is evaluated by fatigue testing. The resulting Wöhler curves indicate the relationship between the number of cycles to failure and the applied stress.

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Process Chain – Additive Manufacturing

Design and manufacturing
Post-processing
Finishing

Additive manufacturing (AM) relies much more heavily on practical experience in the various stages of the process than any other production method. The challenges posed by post-processing are often underestimated. toolcraft covers the complete process chain under one roof, rounding it off on the digital side with an end-to-end software solution – Siemens NX. toolcraft’s in-house quality assurance lab sets new standards.

01
Design

toolcraft designs components or redesigns them using reverse engineering so that they can be produced using additive manufacturing. We conduct topology optimisation using the finite element method (FEM) so that we always produce the most favourable basic design.

02
Simulation

Our warpage simulation technology and our expert staff mean we successfully follow the first-time-right principle.

03
Materials analysis

Particle-size distribution, oxygen and nitrogen content are very important factors in additive manufacturing. The toolcraft measuring and testing laboratory guarantees precise answers for reliable component quality.

04
Additive manufacturing

The individual part is manufactured by applying material layer by layer. The production part is created directly from 3D CAD data. No machining tools are necessary.

05
Depowdering

After components have been manufactured using laser powder bed fusion, the powder is cleared superficially from around their edges, before the components are sent for complete, automated depowdering. The objective of this is to clear them of powder for the subsequent processes and for operational safety reasons.

06
Quality assurance during the process

Qualified visual inspectors check the components after the various process steps. Depending on the requirements, optical measurements are also carried out.

07
Heat treatment

In order to reduce tension in the components and obtain the required mechanical properties, degrees of hardness and microstructure, we carry out heat treatment in a chamber, convection or vacuum furnace, or using hot isostatic pressing (HIP), depending on the project’s specific requirements.

08
Separation from the building panel

Depending on how they are connected and the subsequent processing steps, components made using laser powder bed fusion are separated from the building board using a special AM saw or electrical discharge machining (EDM), or by hand.

09
Removal of the supporting structures

Once they have been separated from the building board, the supporting structures are removed mechanically or manually, and freeform surfaces are reworked using machining techniques. Suitable workbenches with active suction are available for this purpose.

10
Surface finish

Depending on requirements, we produce technically and visually flawless surfaces using blasting processes, drag finishing, vibratory finishing, electropolishing, abrasive flow machining or chemical processes.

11
Machining further processing

From device concepts and combinations of turning and milling, to spark erosion using wire cutting or electrical discharge machining, we use our decades of experience in traditional manufacturing methods to refine your components.

12
Quality assurance

Depending on your requirements, we may perform tactile and optical measuring in our in-house quality assurance department. In our lab, we not only analyse the powder used, but also inspect the properties of additively manufactured test pieces, as these are representative of the subsequently produced components.

Insights

As pioneers, we work with our partners to set new processing standards and conduct groundbreaking projects to make advancements in additive manufacturing. Find out more!

Additive Manufacturing –
Key technology of the future.

Convincing: How you as our customer can take advantage of additive manufacturing

Greater freedom of design.

Even the most complex geometries are possible.

Broader range of applications.

Also suitable for materials that are hard to machine.

Versatile technology.

Besides being used in laser powder bed fusion, the powder nozzle can repair defective components, apply coatings and wear protection, and produce hybrid structures.

Clear time and resource savings.

Parts manufactured within a few days, no need for tooling.

Profitability.

Weight reduction by means of FEM calculations and topology optimisation.

Innovation potential.

As your partner in research and development, we open new perspectives and market opportunities for you.

Verified quality.

Analysis of materials and additively manufactured samples (micrograph analysis, tensile strength testing, microstructure analyses, fatigue testing etc.)

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 1.4404 und 1.2709
Pure copper and copper alloys, such as CuCr1Zr

Media library

Gain a direct insight into what we can do for you.

3D-printed injection moulding tool realized in cooperation with Siemens NX

Komplette Prozesskette im 3D-Druck in Metall mit Siemens NX

Case Studies

Examples of our work – clearly organised for your reading pleasure

Automotive and vehicle technology

Turbine blade wheel - reducing the assembly time

The redesign of a turbine blade wheel has reduced the installation work required for replacement and increased the output of the steam generator. Deutsche Bahn used our complete additive process chain for the project.

Additive manufacturing

Medical Technology

Keeping a handle on everything

As a leading supplier of motor systems, Aesculap sells products for use in various areas of medicine, such as orthopaedics, traumatology, heart surgery and dermatology. One such example is its battery-operated motor system Acculan. To produce the battery casing for this motor system, toolcraft used additive manufacturing.

Additive manufacturing

Medical Technology

Internally cooled bone drill for the operating theatre

On behalf of the IFW of the University of Hanover, toolcraft developed and manufactured a bone drill with closed internal cooling using 3D printing. This prevents both temperature-related tissue damage and the escape of cooling fluid.

Additive manufacturing

Automotive and vehicle technology

Föhl company

The plants of Adolf Föhl GmbH + Co KG supply several hundred million zinc diecastings and plastic injection mouldings each year. This enormous output indicates the dimension of the increase in productivity which the company way able to achieve thanks to toolcraft's metal laser melting technology.

Additive manufacturing
Injection moulding + mould making

Semiconductor and optical industry

Mould with an optimised topology

In an internal project we developed and implemented a mould for manufacturing a plastic part for the optical industry. The 3D-printed, topology-optimized result: 50% less mass and 30% faster cycle time with the same component quality.

Additive manufacturing
Injection moulding + mould making

Motorsports

Engine bracket - lower weight without a drop in performance

The motor sports university group of the FAU Erlangen-Nuremberg commissioned toolcraft with the design and 3D printing of an engine bracket. By topology optimization a maximum weight and component reduction was achieved with the same fatigue strength.

Additive manufacturing

Uncover your potential for innovation.

Your Pace makers for additive manufacturing

As your research and development partner, we can help you explore new avenues of business and market opportunities. Find out more about Cross-Dimensional Manufacturing, our unique consulting and manufacturing standard.

Challenge us to help you with your projects today!

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Phone +49 9172 6956-0