Additive Manufacturing with Parallelkinematic Modules: 3DMD Process with Machining of Large Parts

What is the 3DMD Process?

Dynamic Material Deposition (3DMD) combines powder-based laser deposition welding with Additive Manufacturing of metallic components. In this process, a laser melts the material which is then deposited onto a substrate. This method speeds up production, decreases energy consumption, and minimizes warping.

The Challenge of Size in Additive Manufacturing

Additive Manufacturing has a notable limitation: while it produces small parts with high precision, large components often lack detail and quality. The hybrid SigmaTau equipped with a DED (Directed Energy Deposition) or a 3DMD process addresses this issue, enabling economical production of large components without sacrificing precision.

Versatility and Applications of 3DMD

Originally, the 3DMD process was primarily used for coating components. However, its capability to process various alloys and metals through a nozzle-based powder supply makes it extremely versatile. Applications include:

• Protective coatings that extend the lifespan of components
• Specialized surface treatments
• Reinforcement features for lightweight construction, leading to material cost savings
• Repair of components, as well as traditional Additive Manufacturing

Precision Manufacturing of large parts: The Integration of 3DMD in the Parallelkinematic Module (PKM)

Together with Cognibotics and technology partner Ponticon, ELHA-MASCHINENBAU has successfully integrated the dynamic material separation process (3DMD) into the PKM. This collaboration has resulted in a versatile system that is able to handle the production and machining of complicated components made from a variety of alloys and elementary metals.

• The Parallelkinematic Module handles both the manufacturing and post-processing of intricate parts made from various alloys and metals within a single setup. This includes:
  • Additive manufacturing 
  • Coating
  • Reparation
  • Post-processing and machining in the same setup
• Large-Area Production: Supports the fabrication of large-area components within a work envelope up to 3 x 2 meters in the Y x Z dimensions, with an extensive range in the X dimension, ensuring precise outcomes and near net-shape structures.
• Exceptional Dynamics: Achieves maximum accelerations of 2.5 G, significantly enhancing manufacturing speed and operational capabilities, especially for directional changes and contour fidelity.
• Microstructure Fabrication: Produces 3D microstructures with a minimum wall thickness of 500 μm and a surface roughness of approximately 20 μm.

Mobile Hybrid Additive Manufacturing Turn Key Solution

In addition, a more compact version of the PKM was designed in this way, to fit inside a standard 40-foot container, providing a workspace measuring 1.2×1.2×2.5 meters. This design facilitates easy transportation and supports additive manufacturing and machining operations within a single setup. It offers the versatility to handle both production and repairs, whether in-house or on-site. Additionally, an advanced calibration system quickly restores precision after transportation, maintaining consistent accuracy in any environment.

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General information on the 3DMD process

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