Laser Powder Bed Fusion (LPBF), also known as Selective Laser Melting (SLM) or Powder Bed Fusion (PBF), is an advanced additive manufacturing technique used primarily for metal parts. Let’s dive into how this fascinating process works:
- Layer-by-Layer Building:
- LPBF builds parts layer by layer using a powder bed as the raw material.
- Here’s how it unfolds:
- A thin layer of metal powder is spread across a substrate (usually a metal plate) using a recoater blade or roller.
- A high-energy laser beam selectively melts the powder particles in the desired pattern for the current layer.
- The melted powder solidifies, fusing with the previous layer.
- The process repeats, adding one layer at a time until the entire part is complete.
- Laser Precision:
- The laser beam scans the powder bed with incredible precision, melting only the areas where the part geometry dictates.
- This localized melting ensures accurate and intricate shapes can be produced.
- Material Properties:
- LPBF allows for the creation of complex metal parts with excellent mechanical properties.
- The resulting parts exhibit high strength, good fatigue resistance, and can withstand extreme conditions.
- Applications:
- Aerospace: LPBF is used to manufacture lightweight, high-performance components for aircraft engines, turbines, and structural parts.
- Medical: Custom implants, dental prosthetics, and surgical instruments benefit from LPBF’s precision.
- Automotive: Engine components, brackets, and lightweight structures.
- Tooling: Complex molds, dies, and inserts.
MagnaVol Manufacturing Solutions seeks to address the two largest challenges the industry faces today
- Small build volumes - parts are currently restricted to 400mm³, which is too small to add significant economic value
- OEM machines - Customers are forced to spend over $1M on printers and then must operate them internally, driving up ownership costs further.
We operate as a print-as-a-service company, using highly customized large format printers to achieve the highest quality, lowest cost prints available today. We plan to offer unmatched print volumes exceeding 1200mm³ allowing us to print massive numbers of smaller parts or large volume monolithic parts to customers ranging from aerospace to automotive to defense. Kevin Campbell and Peter Karkos have a combined 20 years' experience in metal additive, including parts that have reached and remain in low earth orbit. Their expertise lies in the process development and machine operations. Mr. Campbell previously led operations at ABL Space Systems and Freeform Future Corp. Mr. Karkos previously led all additive and machining efforts at ABL Space Systems and Blue Origin, which aerospace design experience from Pratt & Whitney.
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