Wayland Additive returns to Formnext with the Calibur3 system and puts the spotlight on NeuBeam, an electron-beam variant of powder bed fusion (PBF). The technology targets applications in aerospace, energy, and defense where high part quality and robust processing of demanding alloys are required. At booth 12.0 B139, Wayland will demonstrate parts made from various materials as well as a Calibur3 machine on site.
NeuBeam differs from classic e-beam systems through active charge neutralisation (ACN) during the build process. This approach is intended to avoid wide-area pre-sintering of the powder bed, thereby supporting design freedom, a broader range of materials, and reduced post-processing.
“Our message at Formnext this year is clear. NeuBeam is not a science experiment, it’s industrially viable and delivering results,” said Peter Hansford, Chief Revenue Officer at Wayland Additive. “The installation of our technology at the RAF facility and the subsequent flight qualification of a critical titanium part are major milestones, not just for us, but for the broader AM industry. It proves that NeuBeam is more than disruptive theory. It’s trusted to perform where failure is not an option.”
At the show, Wayland also plans to present material data sheets for Inconel 718, making transparent the ongoing parameter and quality development for one of the most sought-after nickel-based alloys in aerospace and energy. An accompanying talk by the Head of New Technologies will explain process windows, part integrity, and the resolution of large, complex geometries.
Hansford also noted the system’s appeal to industries working with difficult materials. “What sets NeuBeam apart is its ability to handle challenging metals without the constraints seen in traditional e-beam systems. Our unique Active Charge Neutralisation (ACN) during the build process, eliminates the need for wide-area sintering. This opens the door to a broader material palette, greater design freedom, and reduced post-processing, all essential for industries facing tight tolerance and performance requirements.”
For users, the combined approach of ACN control and e-beam PBF potentially means tighter tolerances with less rework, as well as options for localized spare-parts production. If the demonstrated performance is confirmed in further series environments, NeuBeam can serve as a building block for reproducibly qualifying parts with critical requirements—from prototype to validated small-series production.
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