New Large Format Metal AM Capabilities at Penn State’s CIMP-3D.

The Center for Innovative Materials Processing through Direct Digital Deposition (CIMP-3D) at Penn State is expanding its world-class capabilities in metal based additive manufacturing technologies with installation three Large Format AM systems: a 3D Systems’ DMP Factory 500 3D printer, a SPEE3D metal AM machine, and a wire-arc additive manufacturing system (WAAM) from ABB Inc.

A 3D Systems DMP Factory 500 was recently installed and commissioned within CIMP-3D at Penn State. The Factory 500 is the best in its class build volume (up to 500 × 500 × 500 mm) and, with multiple lasers, is able to produce parts spanning the entire volume quickly, and offers the ability to produce components from a wide range of metal alloys. This system incorporates novel technologies including coaxial monitoring and a high contrast single-lens reflex (SLR) camera placed directly within the build chamber, allowing for comprehensive in-situ process monitoring of the build. The advanced metal production system includes work modules required for AM of metal components; including the printer module (PTM), a de-powdering module (DPM) for powder removal and recovery, and a powder recycle module (PRM) for pre and post build processing of powder, and storage. Additionally, a GF Machining Solutions Cut AM 500, a dedicated electrical discharge machining (EDM) system, allows for parts to be quickly removed from the build plate. The DMP Factory 500 was installed to support the “Research for Virtual Design and Qualification Process for Additively Manufactured Parts Optimized for Multi-Laser Machines” program awarded through the National Center for Manufacturing Sciences’ (NCMS) Advanced Manufacturing, Materials, and Processes (AMMP) program to a team comprised of 3D Systems, Raytheon Technologies, Combat Capabilities Development Command (DEVCOM) Army Research Laboratory (ARL), Penn State Applied Research Lab, Johns Hopkins University, and Identify3D, with a goal to optimize a component relative to an Army modernization product to maximize cooling and improve overall system performance.

SPEE3D metal AM is a high-speed additive manufacturing process that is built on the cold spray process. In this process, metal powders are accelerated using supersonic gas jets and deposited onto the work piece. The high velocities results in high plastic deformation and strong adhesion of the powder particles to the substrate. Using cold spray technologies, the SPEE3D metal AM system is able to build parts within minutes, instead of hours, making this system one of the fastest and most economical systems available within the additive manufacturing field. In addition, the robust process can be used directly in the field and within harsh environments making this technology an ideal solution for quickly building parts and components at the point of need.

A new wire arc additive manufacturing system (WAAM) from ABB Inc. was also recently installed at the Applied Research Laboratory at Penn State. WAAM may not be well known within the additive manufacturing industry, but it holds one of the biggest potentials for large-scale 3D printing where components are measured not by centimeters but by meters. WAAM builds components by melting a wire forming weld beads onto a substrate using an electric arc heat source. A robotic arm controls the process and, much like most AM processes, the WAAM process builds components layer by layer until the component is completed. Unlike more traditional AM processes, such as powder bed fusion processes, there is no limit to the build envelope, allowing for the production of very large components. This system will further complement the laser based large-scale robotic AM system already located within The Applied Research Laboratory at Penn State. Both systems have their own unique benefits for tackling large scale AM: a laser heat source allows for better melt pool control and opens the ability to use both wire and powder feedstocks while an electric arc heat source offers fast and consistent metal deposition.

With these recent additions, CIMP-3D and Penn State is further growing it already world-class capabilities within metal based additive manufacturing. These systems will further complement the wide range of research directed at Penn State in all aspects of additive manufacturing. In its position as a US Navy University Affiliated Research Center (UARC), several of these AM systems will be capable of processing classified components.

CIMP-3D at Penn State Expands Capabilities in Additive Manufacturing, Pushing the Limits of Precision, Scale, and Flexibility.

The Center for Innovative Materials Processing through Direct Digital Deposition (CIMP-3D) at Penn State is expanding its world-class capabilities in metal-based additive manufacturing (AM) with the recent installation of three large format additive manufacturing systems: a 3D Systems' DMP Factory 500 powder bed fusion additive manufacturing system (PBFAM), a wire-arc additive manufacturing system (WAAM) from ABB Inc., and a SPEE3D cold spray metal AM machine

Multiple lasers are used in the 3D Systems DMP Factory 500 to turn metal powders into solid parts. The system is able to utilize a variety of metal alloys in making precise components impossible to create with traditional manufacturing techniques. This cutting-edge machine includes features such as an internal camera, high speed video and other custom sensors to monitor the build process, as well as modules to recover and recycle metal powders in an inert environment. The DMP Factory 500 was installed at Penn State in support of a program to modernize products for the US Army.

A welding arc connected to a robot expands the scale at which parts can be additively manufactured. The freestanding ABB Wire Arc Additive Manufacturing (WAAM) system does not need to operate in a contained space or manage powders—so it can build large components. The WAAM system is complemented by its larger sister laser-based robot AM system commissioned 2 years ago, which can build parts taller than a person by combining a 12 kW laser with metal powder or wire.

Supersonic gas jets propel powders at such high speeds they stick to parts and can quickly build new parts in the newly installed SPEE3D system. A major advantage of this technology is the ability to use it in the field to manufacture or repair components in minutes, rather than hours. One of the fastest and most economical systems in the additive manufacturing field, it can be deployed where it is needed. This flexibility brings the ability to create new parts into harsh environments.

With these recent additions, CIMP-3D at Penn State is extending its already world-class capabilities within metal-based additive manufacturing. These systems complement the wide range of research conducted at Penn State in all aspects of additive manufacturing.

CIMP-3D Directors Announce Monthly Additive Manufacturing Colloquia

Thanks to the hard work of innumerable faculty, staff, and students across Penn State, our University is now recognized internationally as a leader for Additive Manufacturing research, development, and education. This rings true across all AM-related disciplines---from material science to design-for-AM to process monitoring & control to applications-of-AM to supply chain implications and legal issues. The list goes on, and more opportunities abound.

Recognizing the potential benefits of cross-campus interaction and collaboration, Penn State’s CIMP-3D is kicking off monthly Additive Manufacturing Colloquia. A different topic will be selected each month, and innovators will be invited to present 5-10 minutes on their research to spur lively discussion.

More information can be found here: Event Details

Penn State ARL and CIMP-3D Honor Ed Good for his 28 Years of Service

We congratulate Ed Good on his retirement this year after 28 years as the lead Materials Technologist in the Laser Processing Division/CIMP-3D lab. Ed was responsible for a wide host of activities, including the coordination of the metallographic laboratory, execution of all metallographic activities and identification and coordination of outside characterization techniques such as mechanical testing. Ed was also the primary metallographic trainer for graduate and undergraduate students within the lab. Ed was a major contributor in the renovations, organization and startup of the Center for Innovative Materials Processing through Direct Digital Deposition Laboratory.

CIMP-3D Opens New Advanced Polymer and Multi-Material Additive Manufacturing Lab

CIMP-3D is proud to open a new high-performance additive manufacturing lab for advanced polymers and multimaterial AM (including electronic materials) at 230 Innovation Park. The 1,000 square foot lab is an intercollege and interdisciplinary space that will be used to implement designed materials as well as improve upon existing additive manufacturing and post processing methods. Methods of AM in the space include vat-photo-polymerization, material extrusion, powder bed fusion, material jetting, and binder jetting formats. The lab is being led by Dr. Hickner, Dr. Simpson, Dr. Meisel, Dr. Manogharan, and Dr. Vogt. These lab groups span the departments of Material Science and Engineering, Mechanical and Industrial Engineering, and the Chemical Engineering.

Penn State ARL and CIMP-3D Honor Dr. Rich Martukanitz for his Leadership
and 28 Years of Service

We congratulate Dr. Rich Martukanitz on his retirement this year. Rich was an integral part of the realization of CIMP-3D, widely recognized as a national leader in fundamental and applied R&D for Additive Manufacturing. Dr. Ted Reutzel will serve as Acting Director while a national search is conducted.

Penn State Welcomes Dr. Masahiko Mori as Pioneer in Hybrid AM

Dr. Masahiko Mori, president of DMG MORI, visited Penn State and recieved the 2018 Pioneer in Hybrid Additive Manufacturing Award sponsored by CIMP-3D. Dr. Mori gave a lecture on the evolution of manufacturing and emerging new technologies.

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Dr. Ed DeMeter Recieves DURIP for Advanced Post Processing Equipment

Dr. DeMeter's Defense University Research Instrumentation Program (DURIP) proposal was awarded for 'Super Finishing of Printed Metallic Parts for High Performance Naval Systems'. This award will be used to install a state-of-the-art finishing laboratory within the Penn State FAME Laboratory, and according to De Meter “this award will enable Penn State to play a vital role in meeting critical tolerances of AM parts through advanced secondary machining process technology, such as abrasive and electro-chemical processing”. The award will be used to acquire several advanced finishing systems having a value of over $500,000.

Congratulations to Ed DeMeter and his team; Rich Martukaniz, Sauraph Basu, Guha Monogharan, Hojong Kim, Todd Palmer, Ted Reutzel, Tim Simpson, Jingjing Li, and Robert Voigt

Winners of the Modeling Challenge for Additive Manufacturing

CIMP-3D, DARPA, and America Makes are pleased to announce the winners of the first Modeling Challenge for Additive Manufacturing. Based on comparisons between experimentally obtained data and the submitted simulation results, the team representing Carnegie Mellon University was awarded the highest ranking, followed by a team lead by Applied Optimization, Inc.

The Carnegie Mellon University team was comprised of: Professor Shi-Chune Yao of the Mechanical Engineering Department, Professor Anthony Rollett of the Materials Science & Engineering Department, Professor P. Chris Pistorius of the Materials Science & Engineering Department, and Mr. Patcharapit Promoppatum of the Mechanical Engineering Department.

The Applied Optimization team consisted of Dr. Anil Chaudhary of Applied Optimization and Dr. Suresh Babu of the University of Tennessee, Knoxville. The collaboration between Applied Optimization and the University of Tennessee was made possible through an NASA STTR program.

The two awardees were able to fairly accurately represent the complex motion of the heat source associated with the build, while providing thermal data that reasonably agreed with experimental results. The thermal data enabled the teams to ascertain the operable transformations associated with the nickel-based alloy and approximate the resultant microstructures. A technical publication of the results from the Modeling Challenge, along with experimental data, is being planned.

NAVAIR Flys First 3D-Printed Safety-Critial Parts on MV-22B Osprey

An additively manufactured titanium link and fitting for a V-22 engine nacelle was successfully flown during a test on July 29th at the Naval Air Systems Command (NAVAIR) in Patuxent River, Maryland. The Penn State Applied Research Lab and CIMP-3D were heavily involved in the development of the manufacturing process required to qualify these components for flight.

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CIMP-3D Recieves DURIP for Hybrid System

Funds for a DMG MORI LASERTEC 65 3D were awarded by the Office of Naval Research (ONR) through a Defense University Reserach Instrumentation Program (DURIP). This system will be located at CIMP-3D to begin the development of hybrid additive manufacturing technology.

More information in the links below:

Facility Expansion at Penn State Innovation Park

The CIMP-3D Additive Manufacturing Demonstration Facility at Penn State Innovation Park announced today that it has begun to expand and renovate its laboratory to include a brand new Powder Bed Fusion Lab as well as a dedicated university lab for colaboration within Penn State.

The expansion also includes the addition of two new systems; the 3D Systems ProX 320 and the Objet 350 Connex3 by Stratasys.

New CIMP-3D Partner

CIMP-3D is proud to announce a ground-breaking partnership with 3D Systems. This new collaboration serves as the foundation for the development, advancement, and qualification of cutting-edge high-resolution additive manufacturing technologies.

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