Build bigger, better and faster

A New Metal Additive Manufacturing Era | The MetalFABG2

Transform your manufacturing with the latest MetalFABG2 3D printing system, proven to offer continuous production through automation and driving down costs in aerospace, high tech, energy, automotive, and more. 

Challenges Faced by AM Component Manufacturers

capacity

Capacity Expansion

To enhance production capacity, manufacturers have the option to expand their workforce or invest in more printers, both of which involve significant financial investment.

 

production

Design to Production

Manufacturers frequently prototype and iterate on mid-size printers. Once a production decision is made, switching to a larger format printer becomes difficult since parameters, features, and multi-laser requirements necessitate another costly iteration of the design loop.

development

Development

Those looking to expand the number of materials they can work with have two options: undertake material changes in the same core, which escalates the risk of cross-contamination, or invest in a new printer, which increases the risk of under-utilization.

Automated Industrial Metal Additive Manufacturing

A Modular and Automated metal AM printer: The MetalFABG2

The MetalFAB system can be customized with a range of optional modules that optimize efficiency and automation. We continuously upgrade the MetalFAB system by integrating cutting-edge features and advanced capabilities, ensuring your investment remains up-to-date and future-proof.

MetalFABG2

Core

This is a basic setup with no automation that allows users to choose from 1 to 4 full-field 500W lasers.

 

Benefits:

  • Basic Research and Development
  • Material development
  • Minimal metal powder exposure
  • Opportunity to upgrade with minimal downtime

 

Upgrade Potential:

This configuration can be upgraded with four full-field lasers, an additional core if new material is required, as well as with a robot and an exchange module to facilitate production ramp-up.

MetalFABG2

Automation

This is most effective for those that have started to scale production. We provide a robot module that connects to the system's back end and can automatically extract finished parts and insert new build plates, both introduced via an Exchange module.

 

Benefits:

  • Autonomous changeover
  • The ability to print two back-to-back builds autonomously
  • Automatic handling of both build plates and finished products
  • Minimal metal powder exposure

Upgrade Potential:

This configuration can be upgraded on-site with new cores or with a continuous production form.

MetalFABG2

Continuous Production

A fully automated metal additive manufacturing production cell. This includes a robotic module capable of exchanging finished builds from different cores for new build plates.

 

Benefits:

  • Autonomously runs up to 8 print jobs back-to-back
  • Automates all build plates and finished product handling
  • Prevents metal powder exposure

CTM-overview

Control Module (CTM)

Connecting, monitoring, and conditioning the factory and internal supplies, such as laser light and process gases.

AMC-overview-2

Additive Manufacturing Core (AMC)

Powder handling, such as dosing and recoating

Inert gas flow and environmental control

Build Plate handling

EXP-overview-2

Exposure Module (EXP)

Positioning and docking of the optics enclosure above each core

Controlling the optical beam position and focus

Feedback via cameras and LEDs for vision applications

Thermal conditioning of optics

EXC-Overview-2

Robot and Exchange Module

Loading/unloading of build plates

Store build plates at the exchange or storage module

SMT-Overview--2

Storage Module (STM)

Enables autonomous operation

Store build plates, half-fabricates and finished products

Build your own MetalFABG2

The modules listed above can be configured in a variety of ways to meet your specific needs. Try out our configurator tool to see if you can discover a modular setup that works for you.

1
3
MetalFAB1 Module
 
Controls Module
Controls Module
Controls Module
MetalFAB1 Module
 

Feel free to get in touch so we can walk you through the steps to operate such a system.

Contact a specialist

“We're always excited to hear about the unique parts our users are printing, and we're constantly willing to talk about how the MetalFABG2 could further improve their production.”

Mark Beard

Global Director of Process &
Application Development

Check it out for yourself

Experience the MetalFABG2 difference first-hand

Nothing beats a test drive. Come witness metal additive manufacturing in action at one of our development sites or at a MetalFABG2 user location in a real-life additive manufacturing production environment.

Take your metal additive applications to an industrial level

Automated build changeovers
Productivity Leadership

The MetalFABG2 automates the manual steps of conventional metal 3D printers, ensuring the highest uptime, industry-leading build rates, and the lowest total cost per part. 

Large builds

420 x 420 x 400 mm

Highest build rates

Productivity up to 1.3 kg/hour

Automated Laser Calibration
Reliable Quality

Part reproducibility of the MetalFABG2 is ensured for industrial-quality production through robust machine design and superior laser calibration technology.

Repeatable process

Automated laser calibration

Closed powder handling

Guaranteed powder integrity

Automated Powder Handling
Safety and Ease of Use

The integrated powder handling and automated MetalFABG2 system put the needs and safety of the operator first.

Operator safety

No open powder 

Automated process steps

Easy to operate, reducing the risk of human errors

MetalFABG2 prints up to 8 sequential jobs autonomously

Print up to 8 sequential jobs autonomously

The MetalFABG2 series can automate any workflow that previously required an operator, from remote job starts to de-powdering and sieving to production runs of up to eight sequential tasks.

Reliable and repeatable metal printer system

A reliable and repeatable metal printer system

The MetalFABG2 series combines high productivity with automated calibrations and integrated powder handling for quality printed parts.

Unique automated laser calibrations ensure repeatability
Connect to your Quality System to gather vital process and machine data from the MetalFABG2
MetalFABG2 PLT

Keeping operators safe: Integrated powder handling

The MetalFABG2 maintains metal powder under inert conditions throughout the process, from loading with the optional Powder Load Tool to automated de-powdering and sieving.

No contact with open powder: Protects the operator
Automated powder loading: No mess with plastic bins

Automated de-powdering system: Part comes out clean

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Metal powders to suit your application

The MetalFABG2 materials portfolio

Our MetalFAB portfolio is always expanding: Ni alloys, Ti alloys, Al alloys, Stainless and Tool steels. You name it! 

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Schedule a call with one of our experts

Improve your metal additive manufacturing process with MetalFABG2

Challenge us with your cutting edge application! Let's discuss optimizing your part production to generate a winning business case.

Something you’d like to clear up?

Here is everything you need to know to use the MetalFABG2 like a pro.

Is Metal Additive Manufacturing A Mature Technology?

Yes! Many businesses have adopted the technology, including highly regulated ones like medical and aerospace. Industrial metal additive manufacturing  is utilized to manufacture end parts for usage in demanding environments.

Do I Need To Specifically Design Parts For This Technology?

Every manufacturing technology, whether machining, casting, or forging, has its own set of design constraints or tolerances. It is best to build expressly for AM to reap the full benefits of its design, supply chain, and functionality. Nevertheless, even legacy components that cannot be redesigned are viable candidates for AM. In case you require support, our Additive Studios team can provide guidance on the specifics of your component portfolio.

What Materials Are Most Commonly Used?

Metal Additive Manufacturing is primarily utilized with:

  • Nickel-based superalloys such as 718
  • Steels such as 316L stainless and M300 tool-steel
  • Aluminum alloys such as AlSi10Mg and AlSi7Mg
  • Titanium Ti-6Al-4V

Do I Require Specially Trained Personnel To Adopt This Technology?

Yes, engineers and operators will usually need specialized training. Additive Studios is able to assist with the development of training courses as well as daily operations. This will ensure that your teams can fully capitalize on the advantages of this manufacturing technology while operating the printing systems safely and reliably.

Will This Technology Be Beneficial To All Industries?

Today, only a handful of industries have not yet incorporated metal additive manufacturing. The medical and aerospace sectors were two of the earliest adopters of this technology, driven by the desire for better patient care and lighter weighting. Most start by using additive manufacturing for prototyping to accelerate product development, while others use this technology to identify components that are suitable for final production via metal additive manufacturing.