Innovations from EOS

EOS (eos.info) has launched a new system for laser sintering as well as new materials, a metal as well as a pair of plastics.
  

Based on its experience of having sold some 270 metal-additive manufacturing systems, they’ve developed the EOSINT M 280, which is available with either a 200-Watt fiber laser system or a more powerful, optional, 400-Watt fiber laser. The benefit of the higher-power laser is that it can melt more metal power per second, which means that there are shorter build times and overall higher system productivity. This can translate into reduced cost-per-part thanks to this accelerated throughput. And while on the subject of parts, it is worth noting that this system is capable of part build heights up to 325 mm (12.79 in). (An advantage of this height is that it allows hybrid part building: start with a prefabricated part, then put it in the processing chamber and build additional material on top of it.)

To help assure the quality of the parts produced, there is a gas management system in place that assures a high-velocity laminar flow of protective gas across the entire build area. This is important because it helps create stable melting, which results in more uniform, reproducible part qualities. Builds can be performed under nitrogen and argon gas atmospheres. There is a high-capacity re-circulating filter system that’s part of the overall gas management system that helps assure longer filter life, which contributes to overall cost effectiveness.

To help assure the consistency of builds, EOS is deploying the Part Property Management Process for the EOSINT M 280, which uses what’s called “Part Property Profiles.” Essentially, this allows users to define the materials and part properties and to achieve recommended parameter settings (e.g., speed, layer thickness) to achieve consistent part builds.

The EOSINT M 280 is capable of handling ten series materials that the company makes available, including the newest, EOS NickelAlloy IN625.

EOS NickelAlloy IN625 exhibits properties including high tensile strength, high processability, and overall corrosion resistance. The material is said to be applicable in aerospace, chemical, motor sport, and marine industry applications. One of the early users of this new alloy is Greg Morris of Morris Technologies (see: timecompression.com/articles/rapid-tooling-faster-better-and-less-expensive). About it, he says, “We are using IN625 with DMLS [direct metal laser sintering] to build complex aerospace parts for high-temperature and high-strength applications. The process achieves material properties that are comparable to wrought metals and far exceed casting. For prototyping projects, DMLS saves our customer weeks and often thousands of dollars compared with traditional methodologies.”

The other two materials are PrimePart FR (PA 2241 FR) and PrimePart ST (PEBA 2301). The former is a flame-retardant material that’s based on PA 12 polyamide. It has an 11% elongation at break. Because of its refresh rate, it offers economic and ecological benefits. Aerospace applications are an area cited for this engineering plastic.

PrimePart ST is a flexible elastomeric material that provides an array of mechanical properties depending on the laser-exposure strategy deployed. For example, it can be used to make either hard or soft components. Like PrimePart FR, it has an excellent refresh rate. Thanks to its resilience, the material can be used for applications including flexible fasteners, seals, or buffers.