Selective Laser Melting Visions become Reality
2 In 1990, the physicists Dr. Matthias Fockele and Dr. Dieter Schwarze founded the F&S company. As pioneers of Rapid Prototyping, they were globally among the first to develop and produce stereolithography equipment (STL) for the production of plastic prototypes. In 1995, the company started the development of SLM TM technology (Selective Laser Melting) for the production of components made of metallic materials in cooperation with ILT Aachen. As early as 1997, the first patents were applied for. In 1999, the company delivered the world s first SLM TM machine for metals to the Forschungs-zentrum Karlsruhe. In 2004, Dr. Matthias Fockele founded ReaLizer GmbH, another enterprise which focuses on the development and production of SLM TM machines for the manufacture of metal workpieces.
3 Innovation and Partnership As a technology leader in the area of Selective Laser Melting, ReaLizer GmbH was the first company to develop an innovative and novel technology a technology which has been in practical use for more than ten years now. Creativity and innovation, combined with our wealth of experience, allows us to continually optimise and develop this technology. We attach particular importance to a partnership based co-operation with our cus tomers. They in turn appreciate our dedication. We don t waste time with lengthy discussions when it is time to find a solution, we take creative, committed and positive actions. Many tasks and objectives can only be realized in close and trusting co-operation with our customers. In each case, absolute confiden tiality during the exchange of information and knowledge is assured. Because a productive cooperation is not a one-way street, we welcome our customers close involvement in the problem solving and development processes. The only way to attain our goals is to proceed together
4 SLM TM The Technology Layer by layer on the way to the functional workpiece Selective Laser Melting (SLM TM ) is an additive manufacturing method in which the desired components are produced directly from 3D CAD data. Using standard format STL files highly complex parts can be produced from a wide range of metallic materials. With the SLM TM method, the workpiece is constructed in a three-dimensional layered structure. To accomplish this, the metal is applied in thin layers of very fine powder and melted onto those areas where the workpiece is required to be constructed. Depending on the surface quality and production speed requirements, the powder is automatically applied with layer thicknesses of 20 to 100 µm. A powerful fibre laser then selectively melts the designated areas. Optimum focusing provides the laser beam with a very high power density which melts the material with extreme precision. This results in workpieces with an absolute density being produced with wall thicknesses down to 40 µm. When the melting process is finished for the particular layer, the platform is lowered by the respective thickness, and another layer of powder is applied. The workpiece is constructed layer by layer in this manner. The duration of the process, which takes place in an enclosed inert gas atmosphere, is dependent on the amount of material used and the number of layers rather than the complexity of the component. 1 3 2 x-y Scanner 6 5 4 Laser 1 Inert gas (Argon) 2 Recoater (or wiper) 3 Powder container 7 4 Height adjustable work platform 3 Focus Ø 10-50 µm 5 SLM TM component 6 Powder bed 7 minimum laser focus 7 5 6
5 The layer structure facilitates the production of highly complex lattice and honeycomb structures which cannot be produced using other methods. With the SLM TM process, the component design can be optimised for strength with the advantage of weight saving that only this type of technology can deliver. Components of absolute integrity, durability, strength and quality are produced by means of SLM TM, the material properties of which are nearly equal to those of conventionally produced components. Depending on the intended use and just like more conventionally produced components, they can be reworked using any other method. This is what makes SLM TM technology a sensible alternative... When a functional metal component has to be produced from three-dimensional construction data in the shortest possible time. SLM TM makes prototypes available Optimized material usage using the CAD STL quickly and without the time constraints experienced by more conventional processes. This process is not only faster, but also the most economic way to generate a perfectly functional sample. If complex components with hollow or lattice structures cannot be manufactured or only manufactured with very complex methods using conventional processes, SLM TM technology becomes the cost effective solution. When only a limited number or unique of components are to be produced. Compared to the lost-wax casting process, immediate SLM production can often prove more cost effective.
6 ReaLizer in Action SLM 50 for manufacturing Metal Components With the SLM 50, ReaLizer delivers the Industry s first SLM TM desktop machine for manufacturing components made of metal. The desktop device has been designed for the manufacturing of components with a diameter of up to 70 mm and a height of up to 40 mm. Applications An important application for the SLM 50 is the manufacturing of crown frameworks, bridge frameworks or brackets made of cobalt-chrome and gold alloys for the Dental Industry. Following moulding by the dentist, initially a conventional dental die is prepared. The dental technician scans the model and prepares the data for the individual components using special CAD software. Based on this 3D data, the SLM 50 produces exactly fitting dental components quickly and of high quality. The components are absolutely true to size, homogeneous and require only minimal post processing. On the construction platform with a diameter of 70 mm, up to 40 individual components can be manufactured simultaneously. Another field of application for the SLM 50 is the manufacture of jewellery. Many design ideas, that cannot be realized with conventional jewellery casting, become possible with the new SLM-technique. The new fabrication possibility of hollow parts for the jewellery industry is especially attractive. An important advantage of the SLM 50 is the small amount of material needed for the manufacturing of jewellery made of expensive precious metals. The optional integrated stereo microscope offers universities and research institutions fantastic opportunities for process monitoring.universities and research institutions optimal opportunities for process monitoring. Displayed jewelry parts designed by Stilnovo
7 Specifications Construction volume Platform diameter 70 mm, max. construction height 40 mm Thickness of layers 20-50 µm Laser type Power supply Power consumption Argon consumption Dimensions Weight Software Materials Fibre laser 20 to 120 W 16A, 230V 1.0 KW approx. 30 Liter/h W800 x D700 x H500 mm approx. 120 kg ReaLizer Control Software Tool steel, titanium, titanium V4, aluminium, cobalt chrome, stainless steel, Inconel, gold alloys others on request
8 ReaLizer in Action SLM 100 Precision and Perfection The ReaLizer SLM 100 is designed specifically for the production of smaller components where high precision and surface quality are of utmost importance. This machine has a 100 mm high construction area with work platform dimensions of 125x125 mm. This base area permits the use of optics to focus the diameter of the laser beam down to 20 µm. With the corresponding scan strategy, this machine can produce components with delicate structures with a minimum wall thickness down to 60 µm and with high surface quality. With its compact design and ergonomically designed workstation, the ReaLizer SLM 100 is especially suited for use in laboratories and similar environments.
9 SLM 100 specifications Construction volume Platform 125 x 125 mm Max.construction height 200 mm Layer thicknesses 20-100 µm Laser type Power supply Power input Argon consumption Dimensions Weight Software Fibre laser 50 to 200 W 16A, 400V 1.5 kw app. 35 litre/h W900 x D800 x H2400 mm 500 kg ReaLizer control software Materials Tool steel, titanium, titanium V4, aluminium, cobalt chrome, stainless steel, Inconel, ceramic materials under development others on request
10 ReaLizer in Action SLM 300 The All-Round Talent The ReaLizer SLM 300 is designed for all-round use It is suited for laboratories as well as the industrial production of components. The construction volume measures 300 mm x 300 mm x 300 mm and offers great flexibility. The processing area can be utilized to stack several pieces on top of each other or next to each other, whereby maximising the number of components being processed. If a high component throughput is the primary requirement then the SLM 300 can also be equipped with a high-capacity laser with output power up to 1000 W. The standard minimum laser focus of the machine is 55 µm. ReaLizer also offers a fully automated sieving machine, with powder extraction system, which optimally recycles the powder from the processing area. An exchangeable lens module is available as an option for applications requiring a smaller beam spot size. This option may reduce the available construction space but allows the laser beam to be focused to 20 µm to produce structures with high surface quality. The sieving machine The sieving machine by ReaLizer facilitates the optimal recycling of excess metal powder. The ReaLizer PS01 is a fully automated vibration sieving machine with proces sing area powder extraction system. Extraction, sieving and automatic return to a powder container all takes place in a fully inert gas atmosphere. The powder can then be directly returned into the work process. With the stand alone vibration sieving machine ReaLizer PS02, the extracted excess metal powder can be returned into the ReaLizer stainless steel powder bottles.
11 SLM 300 specifications Construction volume 300 x 300 mm, maximum construction height 300 mm Layer thicknesses 20-100 µm Laser type Power supply Power input Argon consumption Dimensions Weight Software Materials Fibre laser 200, 400, 600 or 1000 W 16 A, 400 V 2.5 kw app. 70 litres/h W1800 x D1000 x H2200 mm w/o sieving machine 800 kg ReaLizer control software Tool steel, titanium, titanium V4, aluminium, cobalt chrome, stainless steel, Inconel others on request
12 SLM TM in action Versatile, fast, economical As a rule, SLM TM processes are more economical than conventional processes when production of unique pieces, customized parts, or small batch quantities are required. In this type of production, the cost benefit is usually higher when the number of components produced is low, the complexity of the component is high and the material usage is low. Great cost benefit in small volume production Selective laser melting facilitates the production of more complex workpieces that cannot be produced with other production processes or only with great difficulty. This way, delicate lattice, mesh or net structures, porous structures, or channels running through the workpiece in irregular patterns can be produced without a problem. In the SLM TM machines by ReaLizer, functional metal pieces are produced directly from the CAD construction data quickly and with their mechanical properties equal to that of more conventionally produced workpieces. SLM TM technology can also be utilized to rapidly produce customized human implants from medical 3-D data supplied by a CT or MRT, for example
13 ReaLizer and its customers Know-how, Service, and Trust We are happy to assist our customers during the development and implementation of the SLM TM production processes. In addition to providing innovative hardware and software solutions, we will continue to provide competent assistance to our customers in the on-going optimization of the processes. Within the scope of a cooperative and trusting partnership, we will share Discover new and innovative possibilities with us! our considerable knowledge of this ground breaking technology with you at any time. We are pleased to support you with the optimization of process parameters for your application and the materials utilized, developing an optimum solution considering the required surface quality, precision, and production speed, the optimal design of the parts to be produced, the start-up phase and capability to achieving the required results, as well as the development of test methods for quality assurance.
The innovative way into the future Chances and possibilities The future belongs to SLM TM technology; it is faster and more economical than more conventional processes in many areas. It also enables us to realize many great ideas. There are no limits to creativity in the development of new component designs. With the growing number of standardized applications and materials, this innovative process will continue on its way out of the research labs and development divisions into the production halls. There are already ReaLizer SLM TM machines which have been integrated into industrial production facilities. Designers from all industries will not only see the technical possibilities of the SLM TM technology in the construction of metal parts, but also include this in their plans for future production needs. After all, Selective Laser Melting is generally more economical and faster when material volumes and batch sizes are small. What is more, SLM TM technology facilitates the production of intricate lattice, and hollow honeycomb structures that are impossible to produce with other methods. This alternative technology offers completely new possibilities when the mass of components has to be reduced while maintaining strength and stability. Human and dental medicine will also find unique ways for the production of even more effective customized implants and dental parts with SLM TM technology. With the advancement of SLM TM technology, even the production of larger parts, for example in air and space industries, will no longer be a vision of the future.
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Available to you on the Internet at www.realizer.com ReaLizer GmbH Hauptstraße 35 33178 Borchen Germany Telefon 49 (0) 5251 63232 Telefax 49 (0) 5251 63062 E-Mail info@realizer.com