Introducing the MetalFab 420K:

Kilowatt lasers, industrial quality and high productivity for manufacturers

Built on proven technology, MetalFab 420K is an automated, modular system that unlocks demanding AM production applications

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Built on our proven system architecture and performance, established with a global installation base over 10 years and over 1 million production hours, the MetalFab 420K is an evolution in metal AM system performance offering a step change in quality, productivity and usability for industrial manufacturing.

Find out more below:

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Additive Industries' technology stands out for its exceptional consistency and quality, and from the outset the development of the MetalFab 420K was focussed around building on our proven and innovative MetalFab architecture and market leading position in system automation to create a platform that could further drive the adoption of metal AM for industrial users.

With the objective of pushing productivity to the maximum whilst continuously focussing on quality, the goal was to provide a system with enhanced usability and the potential to unlock more demanding applications, in more demanding materials, whilst driving increased throughput for production parts.

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4 x 1kW full field lasers

Increased productivity
Unlock hard to process materials
Fully controllable to 900W
Theoretical build rate improvements of >3x for AlSi10Mg

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Highly optimised gas flow

Enables increased productivity & quality
Over 2x increase in actual gas flow rate compared to MetalFabG2
Highly homogenous flow with velocity variance <10% across build area

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Automated & in process calibration

Extra level of automation in laser calibrations
Automated checking and calibration of laser-to-laser alignment during a build job, based on system feedback
Ensures laser-to-laser alignment with 50µm tolerance throughout job
Data and reporting generated to support SPC

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Variable beam diameter on demand

Control the laser spot size as a process parameter from 100 to 500µm
Calibrated value minimises spot variation between scanners for a desired beam diameter
Applicable to all vector types
Increase productivity through advanced process development

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Operational system enhancements

New filter design provides improved waste handling and reduced maintenance intervals
Increased cooling capacity
Enhanced oxygen and humidity controls
Enhanced automated powder extraction
Fully integrated powder recovery system to minimise powder loss

Industrial solution for engineering applications

The MetalFab 420K is designed and built to push industrial applications to the next level

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Industrial users requiring high quality part production

Part quality & consistency is critical for demanding applications in industries such as Space and Aerospace, and the MetalFab 420K is built to meet these needs with full field lasers, automated, class leading calibration and highly homogenous gas flow.

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AM manufacturers looking to push their productivity to the next level

The 4 x 1kW full-field lasers, in combination with high gas flow and open architecture in the MetalFab 420K allow users to boost process productivity, and coupled with the automation options create higher throughput of production parts, presenting a viable alternative to die casting

Companies looking to expand into difficult to process materials

The high powered lasers, full control of all process parameters including beam diameter from 100 to 500 micron and minimal gas flow variance across the build plate offer opportunities to develop challenging materials such as high temperature alloys.

Additive manufacturing plays a critical role in our manufacturing and production efforts

The MetalFab 420K gives us the productivity, precision, and reliability we need to move quickly from design iteration to flight hardware. Additive Industries has been a strong partner throughout the beta program, and this next step reflects our confidence in the system’s readiness for production.

Kunal Naik

Senior Manager, Additive Manufacturing, Stoke Space

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Modular & automated system architecture

Run multiple materials concurrently in the same system or boost your productivity & throughput further - the many configurations possible with MetalFab420K give true flexibility.

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Technical specifications

	Specification
Laser:	4 x 1000W Yb-fibre laser (max. allowable power 900W)
Beam diameter:	Variable parameter 100 - 500um
Optical calibrations:	Automated laser to laser & focus and in process laser alignment
Accuracy / reproducibility:	<0.05 mm
Build volume (x,y,z):	420 x 420 x 400 mm (16.54 x 16.54 x 15.75")
Layer thickness:	30-180 um
Powder handling	Fully internal automated extraction sieving & recycling
Build plate	Automated levelling & positioning
Build platform heating	Fully controllable to 175°C
Machine size (w x d x h):	3.9 x 1.9 x 2.5 m (single core configuration)
Shielding gas	Argon (Nitrogen on request)
Compressed air supply	6-10 bar / 1000Ndm³/min
Power supply	3 x 63A
Software	Additive Industries Build Processor (powered by Materialise) / Autodesk Netfabb / Dyndrite LPBF Pro / Dynamic Laser Assignment (DLA)
Materials	Aluminium Alloy AlSi10Mg* - AlSi7Mg0.6 - Scalmalloy / Copper Alloy GRCop-42/ Nickel Alloy IN718* - IN625 /Stainless Steel Alloy 316L (1.4404) / Tool Steel Alloy M300 (1.2709) - M789 / Titanium Alloy Ti6Al4V Grade 5 - Ti6Al4V Grade 23*			*Material available with 420K specific parameter set

Ready to push your industrial applications to the next level and transform your production with the MetalFab 420K?

Or still have questions? Schedule a call with one of our specialists.
Let’s get you on the path to AM success.

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