3D printing solutions developer and service provider 3D Systems recently introduced two new printing materials designed for industrial high-strength corrosion-resistant parts in aerospace, motorsports and automotive applications, as well as semiconductor, energy, and mold making applications. The addition of Certified Scalmalloy and Certified M789 is expected to provide customers with more high-performance materials that can further optimize metal additive manufacturing processes via the company’s Direct Metal Printing (DMP) platform, which produces complex parts using 3D CAD data and a high-precision laser. According to 3D Systems, the two new materials were certified for metal 3D printing use with the help of material manufacturers APWORKS and BÖHLER Edelstahl.
The Scalmalloy material is a high-strength aluminum alloy and is particularly ideal for weight-efficient, load-bearing components, such as passive RF components (e.g., filters and waveguides) and lightweight structural components. Dr. Michael Sheper, Vice President for 3D Systems’ Aerospace and Defense Segment, expressed that this will be especially beneficial for the company’s aerospace customers.
“Scalmalloy has a very attractive strength-to-weight ratio and is more amenable to 3D printing than many conventional high-strength Aluminum alloys. These performance attributes make it ideal for aerospace applications and we are excited to see how our customers will use 3D printed Scalmalloy components to continue to push the envelope with their innovation.”
The material is capable of producing aluminum parts facilitated by fully-developed build styles available via the 3DXpert software for 3D Systems’ DMP Flex 350 and DMP Factory 350 metal 3D printers. Parts using Scalmalloy are also capable of being chemically cleaned for optimal surface finish. This allows manufacturers to easily remove surface residue during post-processing. Other applications for Scalmalloy include metal structural components (e.g., suspension brackets and transmission casings) for motorsports and automotive applications, and fluid flow and thermal management parts for semiconductor applications.
Meanwhile, the M789 will allow additive manufacturers to develop high-strength molds and tooling. These can be hardened up to 52 HRC while remaining free of cobalt. The material was first conceived in response to demands from company partner GF Machining Solutions for a hard, corrosion-resistant tooling steel. M789 is capable of withstanding repetitive manufacturing processes as well as high levels of humidity, making it ideal for long-term advanced additive applications.
Some uses for the new material include mold inserts with conformal cooling for mold making; drill bits and cutting tools for the energy sector; and tire molds, drive train parts, and axle components for automotive applications.
According to Kevin Baughey, Segment Leader for Transportation and Motorsports at 3D Systems, M879 is expected to provide improved accuracy and advancement for automotive customers. This will enable manufacturers to accelerate innovation and use the technology for parts that require higher fidelity and thinner walls, such as die inserts with conformal cooling and tire tread molds.
The company displayed the two new materials at this year’s RAPID + TCT event at the McCormick Place in Chicago.
For more information, visit 3D Systems’ website.