Product category:
Fast prototyping equipment, pattern-making and services
News Release from: MCP Tooling Technologies | Subject: Selective laser melting process
Edited by the Manufacturingtalk Editorial
Team on 09 December 2005
Selective laser melting makes usuable
prototypes
The functionality of prototypes built using slective laser melting was proven by producing a fully functional prototype of a novel conveyor cleaning system for a major bakery.
The functionality of prototypes built using MCP's Selective Laser Melting (SLM) process was recently proven by industrial product designer, Keith Handy, when he discovered that SLM enabled him to not only produce a fully functional prototype of a conveyor cleaning system for a major bakery client, but also delivered the only possible method of designing something which had previously been impossible to manufacture! MCP Tooling Technologies' Selective Laser Melting (SLM) process produces 100% dense metal parts direct from CAD data using customary metal powder Handy's challenge had been to design a steam cleaning system to remove the build up of bread crumbs and cooking oils from plastic chain conveyors
This article was originally published on Manufacturingtalk on 17 Aug 2001 at 8.00am (UK)
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Previously it had not been possible to clean the chain in situ and therefore had to be replaced every year at high cost.
Delivering the powerful steam jets onto the small fast moving chain belts was the most significant part of the challenge as steam has to be applied close to the nozzles to be effective.
Various aluminium manifolds were machined, anodised and assembled with proprietary jet nozzles.
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However the size limitations meant that there were always some parts of the chain not being cleaned.
Several versions were tried and although the results were promising the cleanliness was only reaching about 70% of the chain, also the process was slow, requiring several passes of the belt.
Handy was then introduced to SLM technology.
He created a 3D design the following day and emailed a stereolithography file to the SLM operator.
The SLM manifold was ready for collection and tested at the bakery two days later.
The test showed a great improvement (85% clean).
A further manifold was designed and produced in the same way and further tests have showed a full clean in one pass.
The manifolds are now being integrated into a production design for the customer and there are plans to sell the product to other bakeries.
Handy explains, "What the process did for me as a designer was to enable me to design a hollow three-dimensional manifold with pre-determined steam nozzle positions at specific angles to clean each critical point of the chain.
I did not have to worry about part lines, assembly techniques or post-finishing for this application.
In effect I was designing something that was otherwise impossible to manufacture - it was like being back at college again! I was able to integrate a 1/4" BSP thread in the CAD file to attach the steam fitting.
The result is a manifold that delivers 10 bar steam through ten jets at multiple angles, all within a single component that is 50mm x 50mm x 50mm." SLM parts are built layer by layer with the metal powder being melted locally by an intensive infrared laser beam that traces the layer geometry.
Very fine details are achievable such as thin vertical walls of less than 100 micron thickness.
Directly after the production process the manufactured parts or tools currently show a surface roughness of approximately 10 - 30 microns Rz.
Although SLM was first released commercially to satisfy the demand for metal prototype production, as the process is refined and developed in terms of process speed, part resolution, surface quality and usable metals, it is anticipated that it will eventually be taken up more widely for end production.
Currently SLM has the capacity to process H13 tool steel, stainless steels (including 316L), titanium (commercially pure and 6,4 are currently in use), copper, cobalt chrome, tantalum (used for medical implants) and Inconels (aerospace).
Early commercial projects include the production of dental crowns and bridges and medical devices such as surgical drilling guides.
SLM processing of further highly reflective metals such as gold, silver and aluminium is now nearing the end of development. Request a free brochure from MCP Tooling Technologies ...
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