Image credit: EOS
Image credit: EOS

EOS, the worldwide technology and quality leader for high-end additive manufacturing (AM) solutions, will present its extensive and growing portfolio of machines, peripheral equipment, software and certified powder materials for producing metal and polymer components at MACH 2016. A variety of service and consulting products that support customers at each phase of the value-added process will also be showcased.

EOS M 100 metal AM system

Ideal for companies considering their first use of additive manufacturing, the new, modular M 100 DMLS (direct metal laser sintering) machine from EOS offers reproducible parts quality. It is due to the optimum and consistent processing conditions ensured by the high quality and stability of its 200 Watt fibre laser beam. Moreover, the small spot size with excellent detail resolution enables highly complex and delicate components to be manufactured.

With its small build volume based on a 100 mm diameter platform, the cost effective system is capable of economical production of small quantities, thanks in part to its efficient recoating and exposure strategy, which reduces non-productive time. For example, it can produce approximately 70 dental crowns and bridges in a single, three-hour build. Efficient handling and component changeover result in short set-up times, increasing productivity, while operator safety and ergonomics have been improved.

Due to its modular interior construction, the system can be dismantled quickly, facilitating speedy material replacement and maintenance. The peripheral equipment minimises powder contact and is consistent with an industrial production process. Currently, two types of material may be processed, EOS CobaltChrome SP2 (CE-certified, CE 0537) and EOS StainlessSteel 316L, while EOS Titanium Ti64 will be available shortly.

Real-time, automatic process monitoring during AM of metal parts

An add-on to the EOS M 290 DMLS system, EOSTATE MeltPool Monitoring is an innovative, powerful tool that paves the way for complete parts traceability as well as automated surveillance and analysis of the melt pool during the build process for every spot on every layer on every part.

Developed jointly with plasmo Industrietechnik GmbH, a global supplier of automated, high technology quality assurance systems, it expands EOS’s existing, comprehensive portfolio of monitoring solutions for AM by adding high performance online monitoring for even greater transparency of the complex build process. The technology therefore targets R&D and manufacturing customers with demanding quality requirements.

Reliable quality assurance tools play an important role in boosting trust in a technology. The decisive factor for customers on the road towards series manufacturing based on AM is reproducible, top-quality components at the lowest cost per part possible. EOSTATE MeltPool Monitoring allows the quality assurance to be moved from post- to in-process, not only supporting better risk management, but also reducing cost per part as well as the time and costs associated with quality assurance.

EOSTATE MeltPool observes the light emitted by the melt pool. The key elements are a pair of photodiodes located on- and off-axis, a camera adapter, a specialised signal amplifier and spectral filters to separate process light from reflected laser light. The associated software offers automatic data error correction and real-time process visualisation and evaluation.

For data analysis, the EOSTATE MeltPool Toolbox visualises data in 2D or 3D mappings and enables the evaluation of indication clusters. The tool operates based on three advanced algorithms to obtain different data interpretations. From the collected data, conclusions for the resulting quality in the final part can be drawn, according to customer-defined parameters.

New metal powder

In addition, EOS will introduce a new metal powder to the market, EOS StainlessSteel CX, for mould and tool manufacture. The material is an extremely corrosion-resistant stainless steel with maximum stability and excellent hardness. It is ideally suited to the manufacture of injection mould tools that are used to make medical products or products made of corrosive plastics.

Following the DMLS build process, components made with the material can be easily machined and polished. The stainless steel is resistant to most corrosive plastics and dilute acids, making it the first choice for many demanding industrial applications. Due to its corrosion resistance, EOS StainlessSteel CX also reduces tool wear and maintenance costs.

This story is reprinted from material from EOS, with editorial changes made by Materials Today. The views expressed in this article do not necessarily represent those of Elsevier.”