Productivity Leadership Challenge

As productivity leaders we often get challenged to push the boundaries of what’s possible in metal additive manufacturing. Every week, for the 10 weeks in the run up to Formnext, we will show how to achieve the promise of additive manufacturing through all the aspects of manufacturing end-use parts, what productivity means, how to achieve both quality and  low part price, and even show you what this means in practice to our customers.

Episode 10 - Rocket to the moon: replacing casting with AM

We made it to our final episode! We started this process explaining how we constantly challenge ourselves to be productivity leaders. We have showed all the steps you need to follow to ensure quality in multi-laser systems, in order to achieve consistency over large build areas. We showed how to make an accurate and repeatable process through control and alignment of multiple lasers, so they effectively work as one. Then, when combined with smart process and application development, you can truly unlock all the potential of AM with high quality parts built at low cost. Put all these elements together and you can build remarkable things at high deposition rates.

Thank you for joining us for all 10 weeks during our Productivity Leadership Challenge. We hope you enjoyed our journey in productivity leadership, as much as we did! Visit our virtual Formnext booth find more in-depth results & take a closer look at the 150kg part. See the TechTalks & Round Table discussions On Demand, ask the questions to our experts and find out what it takes to become a productivity leader too!

Episode 9 - Lowering costs through application development

Application development is the key to unlocking all of the benefits of additive manufacturing. Often design for AM is limited to the build process itself. Design for manufacture encompasses all elements of post processing too, such as powder removal and heat treatment, which are all automated on the MetalFAB1. Combine this with process parameters optimised for the part and even its features, then you can really open up the promise of AM with quality parts, built at low cost.

Discover an excellent example of improving part accuracy and consistency through application development in our joint case study with GKN Aerospace & Ansys “Utilisation of Process Simulation & Multi-laser Powder Bed Fusion to Produce a Turbine Exhaust Casing ‘H-Sector’”

Next week is our final episode, where we reveal something quite remarkable and just what is possible when you combine all the steps of the previous episodes. Be sure to also register on time for our virtual Formnext event, so you can get all the insider information & in-depth results on what we finally uncover next week.

Episode 8 - Productivity gains through process development

One of the strengths at Additive industries is our Process and Application Development team. As a company we are very customer focussed and would never just sell a machine and leave our customer unsupported. Whether this support is provided though our world class Customer Life Cycle team, or our P&AD team helping them develop the process for their part. Combining the fantastic hardware of the MetalFAB1 with a process optimised for a part can be extremely powerful in lowering the cost per part and opening new opportunities for components that were not economically viable to be produced in AM before.

We are closing in on our final episode, in our journey to show what we doing to ensure we stay productivity leaders – be sure to come back next week

Episode 7 - Let's talk about productivity

One of the things that is often talked about in our industry is productivity. Many times it is communicated as a deposition rate but this doesn’t include time lost where operators remove the parts, or where builds finish in the middle to the night and the machine is left idle. The fully automated MetalFAB1 allows us to talk about metrics such as OEE and uptime that are commonly used in manufacturing other industries. Find out more about how Additive Industries monitor this metrics and why we consider ourselves productivity leaders.

At Additive Industries we constantly challenge ourselves how to make AM more mainstream, and we believe that through making AM a truly production-ready technology we can achieve this. Next week find out more about how our Global Process & Application Development team help our customers.

Episode 6 - Ensuring the three Rs of AM: Repeatability, Reproducibility, Reliability

One of the most important aspects of gaining the acceptance of AM as a mainstream manufacturing technique, is ensuring constancy of the process. Find out more in this episode “Ensuring the three Rs of AM: Repeatability, Reproducibility, Reliability” about what Additive Industries is doing to make sure you can build the same part on a MetalFAB1 regardless of the machine it’s built on, who is operating it and where is it located in the world.

Discover how through our advanced integrated exposure calibrations, you can maintain part quality on multi-laser systems whilst increasing productivity and lowering part cost. Read the white paper 'Exposure calibrations'

We hope you are enjoying our videos so far, keep coming back every week, there’s more interesting things to come…

Episode 5 - When impossible becomes possible

One of the most exciting aspects of Additive manufacturing is the versatility of the technique. Applications can be found in almost every industry, in parts that range from simple brackets to complex assemblies with moving parts and many integrated functions. However, with this much versatility and potential how do you make sure you are really utilising AM to fullest? What are the main drivers in your application? Stop constraining yourself with what are widely considered the limitations of metal AM. Listen to some of our experts and discover how the impossible becomes possible.

Be sure to come back next week to find out about the extremely important topic of ensuring repeatability of the process and what Additive Industries are doing to achieve this.

Episode 4 - Quality in, quality out 

The parts you build in AM are only ever going to be as good as the material you use to make them. With the MetalFAB1s integrated powder handling, where parts are automatically depowered after being built, not only do we make a much safer environment for the operator but the powder is stored in an inert environment from the moment its is produced by our powder suppliers through its entire life cycle in the MetalFAB1. In order to do this we had to become experts in powder.

Find out next week how to maximize the build rate dependant on part requirements

Episode 3 - Gone with the flow

Building parts quicker and lower cost mustn’t be at the expense of quality. The large platform of the MetalFAB1 allows you to build not only large parts but also a greater number of small parts, helping to lower costs further. With multiple lasers, all able to at every point on the large platform, controlling such things as the gas flow become critical in achieving the desired quality

Next week, find out why the parts you make are only as good as the material used to make them.

Read the white paper 'Size matters: Size matters: Shielding gas flow configuration'

Episode 2 - Power-up & Stay in control

One of the things people first associate with increasing productivity in Laser Powder Bed Fusion is increasing the number of lasers working at any one time. The full field lasers on the MetalFAB1 have many advantages as all lasers effectively work as one, meaning no visual stitching lines on parts, or overlap regions where the part is scanned twice leaving undesirable material properties. In this episode find out how Additive Industries provide the user the ability to control all these lasers exactly how you want whilst still ensuring quality

Join us next week to find out how we maintain the quality of parts, no matter where they are built on the large platform of MetalFAB1

Sigma Labs and Additive Industries announce MetalFAB1 certified as PrintRite3D® Ready

Episode 1 - Leading in Productivity

The first important part of being productivity leaders is the hardware of our MetalFAB1. Mark Vaes, CEO/CTO of Additive Industries, explains company’s vision, mission and focus, but also the importance of the unique design of MetalFAB1

We hope you enjoyed the first episode of our journey to show the steps that are necessary in achieving high productivity. Join us for the next 9 episodes to learn what ingredients are required to also become productivity leaders and to see all the steps of the Additive Industries journey of revealing something special in the week of Formnext!

Get in touch