Breaking the Mold: Revolutionizing Metal Component Production with ColdMetalFusion
In a groundbreaking collaboration, Headmade Materials, AM Solutions, and Neue Materialien Bayreuth are working together to revolutionize the metal component production process. Their goal is to streamline Headmade’s unique ColdMetalFusion technology into a continuous process, offering cost-efficiency and better shrinkage control compared to alternative methods.
ColdMetalFusion utilizes existing polymer powder bed fusion machines, along with innovative solvent debinding and sintering techniques, to produce metal components. While the process involves multiple steps, it remains cost-efficient and delivers superior results. Specifically, ColdMetalFusion has proven to be an attractive technology for producing large batches of parts, especially those measuring a few centimeters, in materials like 316 stainless steel.
To further enhance the technology’s appeal, the partners are focusing on reducing part costs and improving yields. They aim to automate the depowdering and surface treatment processes, recognizing that component handling is the key to industrial production with low scrap rates.
Christian Staudigel, Co-CEO of Headmade Materials, believes that the full potential of additive series manufacturing lies in the automation of unpacking and surface processing. He sees the collaboration as an opportunity to reach a new level and offer a fully automated solution.
Dr. Till Merkel, Division Manager Technology at Rösler Oberflächentechnik, the parent company of AM Solutions, is confident that their experience in surface processing, combined with the scalability of ColdMetalFusion and the research know-how of Neue Materialien Bayreuth, will revolutionize additive metal series production.
One of the most appealing aspects of ColdMetalFusion is its ability to repurpose existing polymer powder bed fusion equipment for metal component production. This feature makes the technology particularly attractive to polymer service bureaus interested in venturing into metal 3D printing. The process is simpler than traditional metal powder bed fusion and opens the door for new polymer equipment to be utilized in large-scale metal component manufacturing.
Transitioning to series metal production using ColdMetalFusion has the potential for significant cost savings, amounting to hundreds of thousands of dollars. This cost-effectiveness, coupled with the availability of a wide range of materials, including exotic options like tungsten and commercially pure Titanium CP T1, makes ColdMetalFusion a highly compelling addition to the toolkit of metal component manufacturers.
Tungsten, known for its difficult machinability, has various applications in CT scanner screens, electronics, nuclear energy, and balancing Formula 1 cars. M2 tool steel, another versatile material, finds use in tooling, knives, cutting blades, and dies. Alongside more conventional materials like Ti64, 316L, and 17-4 PH steel, ColdMetalFusion technology enables the production of a wide array of parts.
While ColdMetalFusion has the potential for diverse applications, Headmade Materials showcases its capabilities with everyday items like bike pedals and gear hubs on their website. These components are commonly produced in large quantities, making them ideal for cost-effective production using ColdMetalFusion.
As Headmade and its partners continue to streamline the process from the initial “green” state to the final product, ColdMetalFusion has the potential to become a game-changer in the metal component production industry. It offers a compelling solution for producing commonplace metal components in a cost-effective manner.
By staying up-to-date on all the latest news from the 3D printing industry and receiving information and offers from third-party vendors, manufacturers can ensure they don’t miss out on the exciting advancements made possible by technologies like ColdMetalFusion.
“Why did the 3D printer go to therapy? Because it had too many layers of unresolved issues!”
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