University invests in metallic rapid prototyping

Liverpool University has invested in what is believed to be the most developed rapid prototyping process for the manufacture of metal components direct from elementary metal powders.

According to Dr Chris Sutcliffe "SLM is the most developed Rapid Prototyping (RP) process for the manufacture of metal components direct from elementary metal powders".

Liverpool University is the first UK based institution to purchase and install an MCP RealizerSLM with Selective Laser Melting Technology developed by MCP Tooling Technologies.

The Equipment was purchased only after all competitors had taken part in a stiff benchmarking procedure to produce ultra light mesh structures in pure steel for permanent bone replacement purposes.

The ultra light bone structures in stainless steel (1.4404; 0316L) and cobalt - chrome, are some of the most complex and dimensionally demanding geometries ever generated in steel, with over 450 holes and channels per cm and sup3;.

In this case, SLM technology reduces the density of pure stainless steel from 7.83 per cm and sup3; to 0.6 g per cm and sup3;.

Nearly 90% reduction in weight but still retaining an enormously strong structure and stiffness with material properties the same as with rolled steel.

New Applications and perspectives are seen in the areas of bio mechanics for implantology of bone structures and also in the aircraft industry for weight reduction applications.

The investment will enable the university to undertake a research project which is part funded by the Engineering and Physical Sciences Research Council (EPSRC).

This project, involving a dedicated team of four academics together with EPSRC research students, will cover research into the manufacture of micro-heat exchangers, ultra-light components and structures for aerospace applications and implantable medical devices.

MCP is supporting the work, in conjunction with Stryker Howmedica Osteonics, a leading manufacturer of implantable devices and Sustainable Energy Systems, which develops sterling engines.

Alongside many industrial applications, SLM is being used in Germany for automated manufacturing of high volume, individual dental caps, crowns and bridges from CT and CAD data files.

Materials include stainless steel (1.4404; 0316L) and cobalt - chrome with material properties better and more durable than castings produced with traditional processes.

The SLM technology offers speed together with a high cost reduction compared to standard dental processes.

The actual cost reduction using SLM compared to standard, traditional dental methods of producing caps and crowns is 40%.

For more complicated bridges the cost saving is around 50% depending on size.

Components produced with the MCP RealizerSLM require no post processing; for example infiltration with other materials or post heat treatment.

The SLM generated material is completely dense and homogenous without pores or voids.

SLM components can be machined using any type of process and can be polished to a very high standard.

Extensive testing shows that many and varied metals and alloys can be processed such as low melt alloys, zinc, bronze, stainless steel, tool steel, titanium and cobalt - chrome alloys.

Concerning materials SLM is the most open and flexible system for producing parts for applications in medical technology.

The MCP RealizerSLM uses a very precise laser beam of only 0.05 mm (50 micron) diameter which builds in steps of only 0.05mm metal parts and components in any complexity and configuration.

The SLM process achieves a building speed of 5cm and sup3; per hour in 100% dense steel.

Compared to other processes, SLM generates components in dense metal and not as composites.

The mechanical properties of finished components are identical to those of the powder materials used in the building process.

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