A New Metal Additive Manufacturing Era | The MetalFab G2

Transform your manufacturing operation with the MetalFab G2 3D printing system, a flexible and scalable platform 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 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.

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

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.

A Modular and Automated metal AM printer: The MetalFab G2

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.

MetalFab G2

Core

The base system: choose from 1 to 4 x 500W lasers, automated powder extraction, sieving, transportation, laser calibration sequence and base plate levelling for job starts - all come as standard. Build plates are loaded and unloaded from the front of the system manually for job changeover.

MetalFab G2

Dual Core

Upgrade the single Core by adding an extra core for new materials or for increased throughput with the same material. This configuration provides an additional fully enclosed powder transport loop so no risk of material contamination if running dissimilar materials. The configuration allows back to back jobs to run without operator intervention or for multiple materials to be processed concurrently in a single machine.

MetalFab G2

Continuous Production

A fully automated metal additive manufacturing production cell. This configuration includes a build plate storage module, exchange module and robot module capable of exchanging finished builds from different cores for new build plates allowing up to 8 sequential jobs to be produced autonomously. The MetalFab G2 Continuous Production configuration can automate any workflow that previously required an operator, from remote job starts to de-powdering and sieving to production runs of sequential tasks.

The MetalFab system architecture provides flexible module configurations to tailor the machine to your unique requirements

Controls Module: Dynamic focus offsets, upgrade laser units with minimal downtime, vibration isolated scanners, chalk filter & chiller
AM Core: 420 x 420mm build area with full field lasers, automated powder extraction, powder handling & job starts
Additional AM Core: Add up to 2 additional AM cores for multi-material printing flexibility and continuous uninterrupted production
Storage Module: Automate build plate exchange for continuous production of up to 8 jobs
Robot & Exchange Module: Transfer build plates & completed print jobs

Take your metal additive applications to an industrial level

Productivity Leadership

The MetalFab G2 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 259.2cm3/hr (Ti6Al4V Productivity Parameter, 4 lasers)

Reliable Quality

Part reproducibility of the MetalFab G2 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

Safety and Ease of Use

The integrated powder handling and automated MetalFab G2 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 MetalFab G2 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.

Contact a consultant to explore your business case

A reliable and repeatable metal printer system

The MetalFab G2 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

Download whitepaper on automated calibrations

Keeping operators safe: Integrated powder handling

The MetalFab G2 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

Metal powders to suit your application

The MetalFab G2 materials portfolio

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

Explore Materials

Build your own MetalFab G2

The MetalFab G2's modular architecture 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.

Would you like a safe operator interface and automated handling?

Do you need autonomous multi-job operation?

Would you like to extend your print capacity and/or use multiple materials. Add cores:

Controls Module

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

Something you’d like to clear up?

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

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.

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.

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

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.

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.

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Improve your metal additive manufacturing process with MetalFab G2

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

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