New laser system optimizes 3D printing processes in the aerospace industry

Additive manufacturing is becoming increasingly important in the aerospace industry, particularly in the production of complex components with high material property requirements. The US company Sintavia has now become the first in North America to commission an industrial multiple laser system with nLIGHT AFX beam shaping technology. The two 1.2 kW lasers installed on an AMCM M290-2 make it possible to variably adjust the shape and size of the laser beam without compromising power or material density. The aim is to increase the efficiency of the powder bed fusion (PBF) process and reduce material losses at the same time.

One of the main challenges in additive manufacturing lies in the balance between layer thickness and material properties. Current systems typically use layer thicknesses of 30 to 45 micrometers to ensure high density and strength of the final product. However, nLIGHT’s beam shaping technology allows layer thicknesses of up to 150 micrometers to be achieved without losing material properties. This results in higher productivity and more efficient use of materials.

“We welcome this new addition to our fleet of printers,” said Brian Neff, Sintavia’s Founder and CEO. “Over the coming years as we develop and apply this new technology, we expect to be able to print our components at layer thicknesses of 150µm or more without losing any material properties, thus greatly increasing the output of our installed printers. The best part of the nLIGHT system, once it is fully tested, is that it can be retrofitted on other existing EOS and AMCM printers with minimal new equipment.”

Another advantage of this technology is the reduction of condensate, which is produced during the PBF process by the evaporation of metal. Studies show that the use of nLIGHT lasers can reduce this amount of waste by up to 70 percent. This not only has a positive impact on the sustainability of the manufacturing process, but also improves material performance, particularly in applications with high creep resistance requirements.

“We can think of no better home for the first dual nLIGHT system in the U.S. than Sintavia,” said Martin Bullemer, Managing Director of AMCM, GmbH. “With their vertically integrated additive manufacturing capabilities, including extensive testing labs, they are well-suited to help develop and expand the capabilities of the nLIGHT laser beam shaping technology.”