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Specifications for Scalable Metal Additive Manufacturing System (10.18.2023)

To meet the rate of output necessary for project success, ORNL is looking to expand their capabilities in metal laser powder bed additive manufacturing. The system specifications that are required are listed below. The metal laser powder bed additive system will allow for large format processing of high temperature materials in an extremely low oxygen content environment. The system will allow for removable print modules to allow for expedient material changeovers as well as 24/7 processing in the system. The system will also conform to space and weight requirements listed below.

Certain non-negotiable features as well as further stretch goals have been identified for the Scalable Metal Additive Manufacturing System. Listed below, a machine is being pursued that…

Specifications:

• Laser power type and quantity: at least qty 3 with at least 500 watt power

• Laser scan overlap at least 30%

• Laser wavelength: 1070 nm

• Laser type: Fiber laser

• Laser calibration capabilities and required accessories will be included with the system

• Laser scanner calibration checks will be included in the system

• In-situ processing will be included with the system in the form of layer wise imaging

• Software packages for in-situ processing monitoring of the layer wise imaging will be included with the system

• Layer thickness Adjustable: min. 5 μm, max. 200 μm

• Build volume: at least (x x y x z) 500 x 500 x 500 mm (19.7 x 19.7 x 19.7 in)*, height inclusive of build plate;

• Material deposition: Soft tube recoater and soft blade recoater

• Repeatability: x, y and z = min. 50 μm

• Minimum feature size: 300 μm

• Typical accuracy: ≤ 0.2% with ± 100 μm minimum

• Removable print modules which can be sealed to preserve the inert atmosphere in the module between transfer from the machine to the depowder station

• Printer and removable print modules are designed to allow continuous 24/7 operation of the system

• Full material changeover time in the printer/printer module:
• Vacuum and fill capability for inerting of the print module/printer

• Documented oxygen level below 25 ppm during print cycle

• Depowdering station designed for manual depowdering and unloading of the parts/plate

• Depowdering station material changeover time:
• All-in-one integrated software for the entire AM workflow from CAD/Part design/manipulation to build simulation to scan path generation

• Yearly service contracts with full field service technician support and preventative maintenance will be available past the introductory period (at least 1 year introductory service contract included with system)

• Required processing parameters for IN718 material will be included with the system along with IN718 powder and metal substrates to perform initial test builds for on-site acceptance

• On-site training for printer and software usage

• Installation of all required systems will be included along with site acceptance testing

Available Materials:

• Inconel 718, Ti Gr23, AlSi10Mg, Hastelloy X

Space and Weight Requirements:

• Machine Dimensions uncrated (W x D x H): 3010 x 2350 x 3160 mm (120 x 96 x 126 in)

o Maximum Printer Footprint: 80 square feet

• Printer (excluding print module):
• Printer Module (excluding metal powder):
• Metal Powder Capacity: 250 - 1000 kg (660 - 2210 lb)

Facility Requirements:

• Electrical requirements: 400 V AC 3 phase + N + PE - 50/60 Hz

• Compressed air requirements: 6-10 bar (87-145 psi)

• Argon requirements: 6-10 bar (87- 145 psi)

• Water cooling supplied with printer

Control System and Software:

• Native Design Optimization Software

• Control software suite

• Operating system: Windows 10

• Input data file formats: Native CAD files, STEP, IGES, ACIS Parasolid, STL

• Network type and protocol Ethernet 1 Gbps, RJ-45 plug

Accessories/Peripherals:

• Depowdering station

• Removable printer modules

• Transportation device to move removable printer modules

• Water cooling supplied with printer

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