The Value of Robotic Metal Additive Systems
At One Off Robotics, we utilize the latest technologies in our metal additive systems. All of our systems utilize Directed Energy Deposition to ensure a clean, cost effective print. Read more about this technology and how our systems can benefit your manufacturing process.
Directed Energy Deposition, or DED, is a category of additive manufacturing processes that use a directed heat source to melt a feedstock material such as metal wire or powder. Depending on the technology, this process can utilize a heat source such as a laser or electric arc. DED provides a higher deposition rate compared to other additive processes and enables the creation of large scale parts in a shorter amount of time. The resulting parts are fully dense, with mechanical properties that meet or exceed those of forged or casted parts. Industries that are currently employing DED technologies include aerospace, marine, energy, and automotive. Below are more benefits of DED Additive manufacturing.
Print Speed/Volume
Print speed of One Off Robotics’ DED systems scale up to 4 kilograms per hour, enabling larger parts to be generated in a short period of time. The standard build volume is one cubic meter, and can be extended with the addition of an external positioner and/or linear rail. Multi-robot systems offer the ability to work in parallel to increase the deposition rate, or to begin the finishing process.
A cross-section of our metal additive cell, highlighting the build volume of our system. See our product page for more information.
Near Net Shape
An example of a printed metal part that has been partially finished with a separate machining process.
Image Credit: Fronius.com
The resulting product of DED additive manufacturing is near net shape, meaning the geometry of the printed form requires very little finishing to achieve the desired form. The time spent printing and finishing is much faster when compared to subtractive methods starting from a billet. In addition to time savings, DED processes create minimal material waste, translating to a savings in material costs, and lower buy-to-fly ratio.
Wide Variety of Materials
An up-close look at the metals that can be printed using DED 3D printing. These images were taken from specimens printed using Meltio’s Laser Metal Depostion (LMD) tool.
Image Credit: Meltio3d.com
All of One Off Robotic’s DED systems utilize standard metal wire, which is an economical and widely available feedstock. Compatible materials include mild steel, stainless steel, inconel, zinc, and aluminum. Multi-metal printing is also achievable with some of One Off Robotic’s DED systems.
Feature Addition/Repair
With DED additive manufacturing, it is possible to combine traditional and additive processes to manufacture parts. Complex features that are not feasible with conventional methods can be added to parts generated from traditional means. In addition, parts that are damaged can be repaired using DED technology to infill cracks and imperfections. As with all robotic additive processes, these operations are automated to ensure the highest quality across many different unique parts.
An example of feature addition using DED 3D printing. The spiraling screw geometry was printed on an existing metal pipe manufactured through traditional means. This piece was made using a Fronius Wire Arc Additive Manufacturing (WAAM) system.
Conclusion
DED additive manufacturing offers an economical and robust method to transform the manufacturing industry today. Coupled with the capability and scalability of a robotic system, the potential of DED additive manufacturing is unlimited, providing the freedom to create complex, large-scale forms in a fast, economical method. One Off Robotics offers multiple options when selecting a DED additive system: Wire-Laser Metal Deposition (W-LMD) and Wire Arc Additive Manufacturing (WAAM). Read more on each of our product pages to see which is right for your application.
