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█ Powder-based laser fusing with metals (LaserCUSING)

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“AM Factory of Tomorrow” opens up a great deal of potential with modular machine configurations

From vision to reality: New machine and plant architecture with the seal “Industry 4.0”

Lichtenfels (Germany), November 19th, 2015: At formnext powered by TCT in Frankfurt, Concept Laser presented a new machine and plant architecture. This is a real first which shows that the vision has already become firmly integrated in the company’s strategy. The new, integrated machine concept under the heading of “AM Factory of Tomorrow” promises a new level of Additive Manufacturing in terms of quality, flexibility and increase in performance. The modular integration of the machine technology into the manufacturing environment is amazing thanks

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to a radically new approach in the design of process components. Ultimately, this makes faster and more economic industrial production solutions available. This vision will soon be reality: Concept Laser has announced a market launch by as early as the end of 2016.

The previous solutions for machine and plant technology in the market all relied on

ideas such as “more laser sources,” “more laser power,” “faster build rates” or

“expansion of the build envelope sizes.” The machine technology represented a

“standalone” solution without any consistent integration into the manufacturing

environment. Build job preparation and build job process proceeded sequentially.

Concept Laser is now attempting, with a new machine architecture, to expand the

usually quantitative sections with new, qualitative aspects. “In essence,” says Dr. Florian

Bechmann, Head of R&D at Concept Laser, “it is about splitting up build job

preparation/build job follow-up processing and Additive Manufacturing in any number of

combinable modules. With comparatively large build envelopes, build jobs can be

carried out with a time delay. The intention is that this should drastically reduce the

“downtimes” of previous stand-alone machines. There is plenty of potential here for

improving the level of added value in the production chain. In contrast to purely

quantitative approaches of previous machine concepts, we see here a fundamentally

new approach for advancing industrial series production one step further.”

The new concept of an “AM Factory of Tomorrow”At present, regional printing centers are being created as service providers all around

the globe. This development is characterized by the transition from “prototyping” to a

desire for flexible series production at an industrial level. The AM users experience the




pressure of traditional manufacturing: demand for space, expansion of the machinery,

increasing operating tasks and in particular times. In the new concept from Concept

Laser, interesting solutions are offered in this regard: Production is “decoupled in

machine terms” from the preparation processes. The time window for AM production is

increased to a “24/7 level,” meaning that there is higher availability of all components.

An automated flow of materials palpably reduces the workload for the operators.

Interfaces integrate the laser melting machine into traditional CNC machine technology,

as is important for hybrid parts, for example, but also into downstream processes (post-

processing / finishing).

Decoupling of “pre-production,” “production” and “post-processing” The new plant architecture is characterized essentially by decoupling of “pre-

production,” “production” and “post-processing.” This includes among other things

flexible machine loading and physical separation of the setting-up and disarming

processes. The objective here was to coordinate the process components in a more

targeted way with interfaces and increase the flexibility of the process design to create

an integrated approach. This becomes possible thanks to a consistent modular structure

of “handling stations” and “build and process units” which, in terms of combination and

interlinking, promises considerably greater flexibility and availabilities. It will also be

possible to handle the present diversity of materials better, and ultimately more

economically, through a targeted combination of these modules. For example, in future

the machine user will be able to use the modules to very precisely “customize” the

production assignment in terms of the part geometry or material. All in all, the level of

efficiency and availability of the production system will be markedly increased, along

with a significant reduction in the amount of space required. Simulated production

scenarios have in fact shown that this space can be reduced by up to 85% compared to




the possibilities that exist at present. In addition, the laser power per m 2 is increased

seven-fold. Dr. Florian Bechmann says: “The build rates have increased enormously

thanks to the multilaser technology. The build envelope sizes have also experienced

considerable growth. We now want to use an integrated machine concept to highlight

the possible ways that the approaches of “Industry 4.0” can change Additive

Manufacturing as the manufacturing strategy of the future. There is plenty of potential

here to increase industrial added value and enhance suitability for series production.”

Solutions from the factory building kit – the modular process stationThe process station shown has a build envelope of 400 x 400 x >400 mm 3, laser

sources, process gas management and filter technology are integrated in the module,

and the layer thicknesses are within the usual range. In addition, the machine solution

has a variable focus diameter and will be available optionally with 1, 2 or 4 laser optics

with a laser power ranging from 400-1,000 W. An available redundancy of the lasers will

ensure that, if one laser fails, the remaining three lasers will still cover the entire build

plate – the build job can still be completed. Dr. Florian Bechmann says: “More and more

laser sources only increase the expected speeds to a limited extent. But ultimately they

also increase the level of complexity and dependencies, which can result in vulnerability,

and thus turn the desired positive effect into a negative.”

Solutions from the factory building kit – the modular handling stationThe new handling station has an integrated sieving station and powder management.

There is now no longer any need for containers to be used for transportation between

the machine and sieving station. Unpacking, preparations for the next build job and

sieving therefore take place in a self-contained system without the operator coming into




contact with the powder. But what also makes a modular handling station attractive is

the specific configurations: A handling station can be linked to two process stations to

create a “manufacturing cell.” The factory building kit also enables several handling

stations to be joined together to create a material preparation facility and be physically

separated from the process stations.

Combinations of modules from the factory building kitThe new factory building kit boasts three types of modules: process module, dose

module and “overflow” module, which are to be offered in different heights. What is

remarkable is the direct link between these modules without the use of any pipes or

tubes and their identification via RFID interfaces. Accordingly, the result is a reliable flow

of materials with high material throughputs along with great flexibility when there is a

need to supply different types of materials for the build process and handle them. “In the

future,” says Dr. Florian Bechmann, “we think that AM factories will be largely

automated. The transport of material or entire modules can be envisaged as being done

by driverless transport systems. This could then be the next step in the development.

Additive Manufacturing can be automated to the maximum extent.”

New type of 2-axis coating processThe new machine concept has a new type of 2-axis coating system which enables the

return of the coater to be performed in parallel with exposure. This results in a

considerable time saving during the coating process.

The coater blades, optionally made of rubber, steel or carbon, can be changed

automatically during the build job. This results in several advantages according to Dr.

Florian Bechmann: “An automated tool changing system, as is the case with CNC




machine technology, promises a high level of flexibility, time advantages when setting

up the machine, and reduces the level of manual intervention by the operator. We

deliberately talk here about ‘robust production’.”

Print approved – ask for copy

Info block on 15 years of Concept Laser

In 2001, one year after Concept Laser GmbH was founded as a start-up by Frank

Herzog, the company unveiled the world’s first industrial laser melting machine. Today

the pioneer’s LaserCUSING process has provided him with more than 50 granted

patents and 100 patent applications. 3D metal components are produced with enhanced

features in a digital process chain which it would not be possible to manufacture using

traditional machining methods. With more than 550 machines installed, Concept Laser

is one of the key drivers of powder-based laser melting with metals. The process is also

referred to as a “green technology” due to the way that resources are conserved. For

example, today the aerospace industry, the automotive industry, medical technology

and other sectors focus strategically on 3D metal printing as the manufacturing strategy

of the future and an embodiment of “Industry 4.0.”




Captions █████████████████████████████████████████████

Caption 0: “AM Factory of Tomorrow”: Smart and “robust” production with AM modules

from Concept Laser at an industrial level with a minimal footprint.

Caption 1: Dr. Florian Bechmann, Head of R&D at Concept Laser: “More and more laser

sources only increase the expected speeds to a limited extent. But ultimately they also

increase the level of complexity and dependencies, which can result in vulnerability, and

thus turn the desired positive effect into a negative.”

Caption 2: Basic idea behind the new machine architecture from Concept Laser:

Decoupling the handling unit and process unit

Caption 3: Option for combining a handling station with two process stations

Caption 4: Handling modules may form a central metal powder preparation station

Caption 5: Linking together the “AM Factory of Tomorrow”: The AM Factory of

Tomorrow is set to be a flexibly expandable, high-grade automated and centrally

controllable metal production system which is focused fully on the production

assignments in hand

All photo credits: Concept Laser GmbH, Lichtenfels (Germany)

Contacts ███████████████████████████████████████




Concept Laser GmbHAn der Zeil 8

D-96215 Lichtenfels

Germany

Phone:+49 (0) 9571-1679-0

Internet: www.concept-laser.de

Press contact:Daniel Hund

Phone: +49 (0) 9571 / 1679-251

E-mail: [email protected]

Concept Laser at a glance ██████████████████████████

Concept Laser GmbH is an independent company based in Lichtenfels, Germany. Since its

founding in 2000, it has been a leading innovator in the field of laser melting technology with the

patented LaserCUSING® across many industries.

The term LaserCUSING®, a combination of the C from CONCEPT Laser and the word FUSING

(to fully melt) describes the technology: The fusing process uses 3D CAD data to generate

components layer by layer.

This process allows the production of complex component geometries without tools in order to

implement geometries as components that are difficult or even impossible to achieve with

conventional manufacturing methods.



mailto:[email protected]

http://www.concept-laser.de/


With the LaserCUSING® process, conformal cooling can be used to create tool inserts as well as

direct components for the jewelry, medical, dental, automotive and aerospace industries. This

applies to prototypes and series parts.

The company offers both standard systems and custom concepts for metal laser melting. At

Concept Laser, full-service as an option means that customers can either purchase their own

metal laser melting systems or rely directly on services, including development services.

Laser machining systems from Concept Laser process powder materials made from stainless

steel, hot work tool steels, cobalt-chromium alloy, nickel-base alloy as well as reactive powder

materials such as aluminum and titanium alloys. Precious metals such as gold or silver alloys for

jewelry making are also an option.

LaserCUSING® offers new perspectives in terms of cost and speed for efficient product

development in industries such as:

• Jewelry

• Medical and dental technology

• Aeronautics and space industry

• Tool and mold construction

• Automotive and motor sports

• Mechanical engineering

The systems reduce development time and costs substantially while offering much greater

flexibility in product development.




The high quality standards, level of experience and successful track record of Concept Laser

guarantee reliable and cost-effective solutions with proven performance in everyday production,

with a particular focus on unit cost reductions.

The art of LaserCUSING® by Concept Laser

Ideas for laser melting with metals in the following areas of application: automotive and motorsport, aerospace, medical and dental technology, die and mold making as well as the wider engineering business.



Documents

PM Concept Laser DE - Metaal Magazine Web viewPR-Concept Laser-11-2015-Formnext-Final-EN.docx. ... to a radically new approach in the design of ... this makes faster and more economic