Last June, French 3D printer manufacturer Prodways announced that it was developing a large-scale metal deposition technology dubbed rapid additive forging (RAF). This would be the third metal additive manufacturing (AM) technology in the company’s growing portfolio, which also includes metal sintering and a form of indirect metal printing with vat polymerization.
RAF is a form of directed energy deposition (DED) that uses a robot equipped with a metal deposition head to deposit metal inside of an inert gas chamber. The objects produced by this method are near net shape and are, therefore, machined to final specifications after the print is complete. Such a process can create large, near net shape metal parts quickly, making it possible to avoid long lead times and reduce metal waste.
Prodways now says that, over the past year, it has demonstrated “mastery” over the RAF process, producing parts without porosity and with homogeneity of the part in all directions. It does so faster than laser sintering and electron beam metal AM processes. The RAF system has a build envelope of 1200mm x 800mm x 500mm (3.9ft x 2.6ft x 1.6ft).
So far, we are not aware of the commercial availability of any of these metal technologies, but Prodways has now announced that it has sold the first RAF machine to Nexteam Group, a Prodways partner that manufactures parts for the aerospace industry. This makes Nexteam Group the first aeronautics company with RAF.
"Nexteam Group's investment is a major milestone in the development of Rapid Additive Forging technology,” said Raphaël Gorgé, president and chief executive officer of Prodways Group. “In partnering with Nexteam Group, which will input its own expertise in machining and finishing services, we are convinced we can ramp this new manufacturing process up to an industrial scale compatible with the technical requirements of major players in the aeronautics and space market."
The machine will be delivered in April, where it will be put to use making aerospace parts. From 2018 to 2019, the technology will be qualified under real operating conditions to prove its repeatability. After that, starting in mid-2019, Nexteam aims to mass produce parts for its clients.
According to Prodways, aircraft and engine manufacturers have ordered parts made with RAF and “validated the relevance of this technology.” Other industries have also expressed interest in using the technology to coat parts or add new features to existing parts.
While RAF fits alongside other DED technologies in terms of the capabilities and applications mentioned here, it does add to Prodways’ existing portfolio in a meaningful way. The company has a goal of becoming the third major company, after Stratasys and 3D Systems, that provides machines, materials and production services. As its portfolio continues to grow significantly, it is realizing that goal.