Additive Manufacturing

FEB 2014

Modern Machine Shop and MoldMaking Technology present ADDITIVE MANUFACTURING, a quarterly supplement reporting on the use of additive processes to manufacture functional parts. More at additivemanufacturinginsight.com.

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F E AT U R E Two Separate Functional Parts, One Design An oil separator and cooler that traditionally function as two separate parts were produced as three components in a direct metal laser sintering (DMLS) platform from EOS, then welded into a single part measuring 450 × 260 × 180 mm (17.7 × 10.3 × 7.1 inches). This was later reproduced in one piece, as a concept design, using the company's new EOSINT M 400 modular, extendable DMLS system above. This part was built from EOS's Aluminum AlSi10Mg alloy for a Rennteam Uni Stuttgart racing car. The upper section of the oil separator/cooler uses centrifugal force to deposit oil from air (its rough surface enhances this effect), and the lower portion serves as the oil tank, offering maximized surface area for cooling. The original part was used in a formula-student racing car and proved to have great performance characteristics, EOS says.  With a build chamber measuring 400 × 400 × 400 mm (15.8 × 15.8 × 15.8 inches), the EOS M 400 enables the automated manufacture of high-quality large metal parts. The system consists of a setup station separate from the build area with an automated system in between that clears loose powder from completed parts. 12— AM Supplement Use of DMLS is said to have contributed to a reduction in the oil separator's size and weight. A highlight of the new system is that it separates job preparation and calculation from the building process, enabling the job fle to be prepared at the designer's desk and then transmitted via a network to the machine. In this way, the machine focuses solely on building the parts.

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