UK engineering firm Wayland Additive recently introduced its newest additive manufacturing (AM) solution product—NeuBeam, an electron beam power bed fusion (PBF) technology. NeuBeam was designed to target relevant sections of a build area, creating a more efficient method of applying heat during the printing process. It also addresses a common problem with PBF: residual stress. The company has stated that not only does it consume less power, but it also produces residual stress-free 3D-printed parts.
The PBF method is one of the most used AM processes for metal. It is characterized by its application of high heat—typically with either a laser or an electron beam—which melts the metal powder layer by layer within a powder bed, hence its name. Wayland decided to adopt a different approach. Instead of a laser, NeuBeam uses an electron beam as the heat source to melt the metal powder. This differs from existing electron beam technology because of NeuBeam’s neutralization capabilities. While the electron beam method can often cause charge accumulation, NeuBeam is capable of neutralizing this, consequently increasing its flexibility with respect to material choice.
NeuBeam aims to overcome and simplify common limitations in manufacturing large components: residual thermal stress and an inefficient powder removal process. The NeuBeam process makes it possible for dense parts to be produced using various materials that are not typically compatible with traditional laser and electron beam systems. This includes refractory metals and highly reflective alloys.
Additionally, the technology offers real-time in-situ part monitoring through structured light scanning, electron imaging and high-speed infrared camera modules. This allows manufacturers to easily modify process parameters, such as the process temperature, even while mid-print. These different monitoring approaches make it possible to see the true temperature of the powder bed as the build is being formed. Microstructures can then be easily optimized and fine-tuned as a part is being built. Likewise, this monitoring system can also be beneficial in material development and research.
Wayland is looking to make a dent in the PBF industry and has recently secured £3 million in investment funding from Longwall Ventures and the Angel CoFund.
For more information, visit Wayland Additive’s website here.
For more stories, check out GE Additive’s largest metal powder bed fusion 3D printer here.