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I3DMFG EOS M400-4

By i3d

I3DMFG First With EOS M400.4 + White Paper

I3DMFG, Inc. has become the first Additive Contract Manufacturer in North America to put into operation an EOS M400.4.  Along with this announcement is a white paper discussing the disruptive nature of Additive Manufacturing and why this is critical for manufacturers, both additive and subtractive.

The EOS M400.4

An ultra-fast quad-laser system with a large building volume. It provides Additive Manufacturing for high-quality parts and is designed for speed and precision.

Four lasers for more productivity

  • Large building volume of 400 x 400 x 400 mm with four 400 watt lasers operating independently
  • The four precise 400 watt fiber lasers operate in a 250 mm x 250 mm square each with an overlap area of 50 mm
  • High build rate of 100 cm³/h

4 Lasers – First-class DMLS quality

  • Exceptional beam and power stability provides highest DMLS part quality
  • All processes running on the EOS M 290 can be transferred to the EOS M 400-4 and deliver equivalent part properties.
  • New and patented EOS ClearFlow Technology ensures consistent process gas management for ideal build conditions
  • Extensive monitoring features ensure high process stability and part quality

I3DMFG is happy to announce that they are the first Additive Contract Manufacturer in the U.S. to have the EOS M400.4 in production.

Additive Manufacturing Disruptive Whitepaper

EOS just released a new white paper discussing the disruptive nature of Additive Manufacturing. The white paper discusses how to approach Additive Manufacturing from three different angles.

One quote that stands out in the article is from Gungor Kara, Additive Minds:

Soon, there will only be two kinds of players – manufacturers who disrupt the market and those whose business is disrupted.

The paper introduces a best-practice approach to becoming an industrial champion in the decade to come as it relates to additive manufacturing and remaining competitive.

You can find the white paper here in our resource library.

 

By i3d

I3DMFG Featured On A2Z Manufacturing Magazine Cover

I3DMFG Featured On A2Z Manufacturing Magazine Cover

I3D Manufacturing is the feature story and on the cover of the latest issues of A2Z Manufacturing Magazine. The story begins on page 26 and can be read right here.

A2Z did an incredible 3-page story highlighting how I3D is leading the way for additive manufacturing as an ITAR registered company and supporting some of the largest aerospace customers with cost-effective, small batch complex and high-value metal parts.

I3D is currently in the process of certifying to AS9100 Rev. D, by Q3 of 2017.

You can find a copy of this entire article here in our DMLS library as well.

By i3d

DIRECT METAL LASER SINTERING (DMLS) FOR CAVITIES AND CORES

You needed your Injection Mold Tooling when? Yesterday??

The Direct Metal Laser Sintering (DMLS) process has been rapidly gaining recognition as perhaps one of the most powerful technologies available in the additive manufacturing world. The recent material parameter developments coupled with outstanding resolution and speed of fabrication are making DMLS cavity and core inserts a very successful tool that can be used to shorten lead times, reduce costs and push multiple projects through in the same amount of time that one project normally takes. i3D Manufacturing can print mold cavity and core inserts within days, giving end-use customers competitive advantages in real time-to-market, product development, and small batch production. Our Aluminum, Maraging Tool Steel and Stainless Steel mold tools can be post processed in all of the same ways as cast or machined parts, from polishing to welding to anodizing. 
 

Interchangeable Cavity and Core Insert Blocks

i3D™ owns North America’s first EOS M290 DMLS 3D Printing machine. As an official Material Process Applications (MPA) for EOS, i3D™ prides itself on its DMLS material and 3D print application innovations. Our interchangeable mold tool cavity and core universal base provides injection molders flexibility in switching out cavity and cores in small and medium batch runs at economical tooling and change-over costs.
 
With the latest, highest quality equipment i3D™  is able to achieve densities at nearly 100%, allowing for any finish requirements to the various 3D printed cavity and cores. Lattice and honeycomb designs specially tailored for optimal part cooling and heating add more value to the mold block design options. Injection molders can offer their clients tool design, manufacture, and part production in as little as 3 weeks. The process is all on-shore, protecting customer designs and avoiding costly tool change expense. Rapid Injection Tooling is often used as a bridge between prototyping and production but, not always. If you have low volume injection molding requirements, rapid tooling could be the answer for you. 
 
Aluminum (AlSi12)
AlSi12 is our most common DMLS Aluminum powder and is perfect for projects with good thermal and low weight considerations. It is an optimal metal for parts with thin walls and complex geometries
Maraging “Tool” Steel (MS1)
Our Maraging Steel powder has excellent strength and mechanical properties. MS1 is a pre-alloyed, ultra high strength powder most commonly used for tooling applications. Its chemical composition corresponds to U.S. 18% Ni, Maraging 300, European 1.2709 and German X3NiCoMoTi 18-9-5. After heat treatment, MS1 typically has a 50-53 HRC.
Stainless Steel (PH1)
PH1 is a medical grade, sterilisable, corrosion resistant steel. It is primarily used in Medical, Firearms, Energy and Automotive applications. After heat treatment, PH1 hardens to 40-45 HRC. Our Stainless steel equivalents include 15-5, 17-4 and 316. Parts made from EOS Stainless Steel PH1 can be machined, spark eroded, welded, micro shot peened, polished and coated if required.
 

      

i3DMFG Metals For Additive Manufacturing

By i3d

Oregon Welcomes i3D MFG™ 3D Metal Printing

Oregon Welcomes i3D MFG™ 3D Metal Printing

Why would a new small business opening in The Dalles, Oregon be newsworthy to Aerospace Manufacturing and Design Magazine? Aerospace is big in the Pacific Northwest and the UAV/UAS giant Insitu is located 20 minutes from i3D™ Manufacturing’s Direct Metal Laser Sintering (DMLS) factory. 3D metal printing has emerged as a critical component in aerospace, rocket, and UAV design and manufacturing, but until 2014, there were no Northwest DMLS service providers. Insitu, Boeing, and the like were forced to use services thousands of miles  away, reducing some of the lead time and cost advantages 3D printing is known for. Oregon is defined by innovation and i3D™’s 3D printing technology is at the forefront of advanced and additive manufacturing. DMLS moves 3D printing from the prototyping realm into true production parts manufacturing. DMLS parts are used in final assemblies by Boeing, Lockheed Martin, GE, etc. In addition to aerospace, i3D™ also provides parts for medical and dental device applications, firearms accessory manufacturers, the energy and recreational gear industries, and automotive parts users.

The Future of Manufacturing

In 2013, manufacturing accounted for 28% of Oregon’s economy, over $65 billion in output. So, its not surprising that the Portland Tribune and Portland Business Journal also featured i3D™ in their Summer 2014 publications. As opposed to traditional, or subtractive manufacturing where parts are carved out of billet, the additive manufacturing process starts with 20-40 micron layers of powdered metal and uses a laser to melt thousands of micro layers together, one layer at a time based on a 3D CAD model – adding material only where the model dictates.  The no-waste process enables parts to be built that cannot be traditionally manufactured, including complex geometries, lattice and honeycomb structures, conformal channels, and single part builds of multi-part assemblies. i3D™ prints stock metals including Titanium, Aluminum, Inconel, 15-5 and 17-4 Stainless Steel, and Maraging Tool Steel as well as custom powders created for specific customer applications. The Dalles has a long history of metal manufacturing and gave i3D™ a warm welcome to its community and the Columbia River Gorge region. Both The Dalles Chronicle and Gorge Technology Alliance celebrated i3D™’s headquarters locating in Oregon. 

By i3d

3D Printed “Buzzing” Handlebars on Your Titanium Bike

When INDUSTRY and Ti Cycles designed their entry for the Oregon Manifest bike design project, their vision required next generation technology and exotic metals that would then be hand-crafted by artisan bike makers into a premier urban commuter bicycle. Creating a beautiful balance between local artisan and new technology meant designing in a completely different mindset – enter, 3D printing. Keeping it local, INDUSTRY brought Oregon-based i3D™ Manufacturing on board to 3D print components that simply could not be manufactured using traditional methods. Included in these custom parts were intricate handlebars housing a bluetooth smartphone app called My Bike which monitors bike maintenance and alerts you to when a light needs to be replaced or when something goes wrong with your brakes. Another software, Discover My City, has a series of curated rides from five of Portland’s coolest residents, which suggests where to ride, eat and shop. The rider simply gets “buzzed” with the alerts, keeping them connected as they commute. Ti Cycles signature tubing Titanium frames are the perfect way to make sure no wires interfere with the rider and preserve the aesthetics of the bike design. The curves and junctions of parts of the frame also needed to be 3D printed because the tubing could not be traditionally manufactured to hold the lines properly. i3D™ printed fork crowns, front and rear dropouts, head tubes, bottom brackets, and seat clusters for the bike. The titanium printed part welds showed superior strength and seamlessly integrated with the tubing. 3D printing and phone apps aside, in the end, it was the skill and craftsmanship of Ti Cycles that brought the high tech and custom bike manufacturing together to create a perfect blend of utility and elegance. Go see what all the “buzz” is about at  3ders.org, Engadgettreehugger, and Bike Portland.

 

i3DMFG 3D Printing Services Recreational Industry

By i3d

i3D MFG™ 3D Prints Titanium Bicycle

i3D™ Manufacturing joined INDUSTRY and Ti Cycles in creating a 3D printed titanium bicycle as Portland’s entry for the 2014 Oregon Manifest Bike Design contest. 3D printing is a perfect solution for those wanting to manufacture a tailor-made product. Whether aesthetics, function, weight reduction, design innovations, or exotic metal cost effectiveness are the goals, additive manufacturing is a game-changer for design and manufacture. Direct Metal Laser Sintering (DMLS) produces functional production parts by fuses 20-40 micron layers of metal powders together from a 3D CAD model. Multiple CAD models can be built on a single run, facilitating cost effective single part production, allowing for multiple versions of the same part to be run simultaneously for evaluation, and reducing lead times from weeks or months to hours and days. Exotic metals like Titanium and Inconel become cost effective because DMLS is a no waste process – after the micro lasers are laser melted together, the left over powder is vacuumed back into the machine and reused. Traditional manufacturing of these costly metals often resulted in as much as 70% scrap, making Titanium cost prohibitive despite its perfect match for the bicycle industry’s weight and strength property requirements. While working with Titanium proved more difficult than other DMLS metals, i3D MFG™ added supports and geometry adjustments for structural rigidity and thermal dissipation to offset tolerance and creep issues created by mass, height, and stress relief. Custom latticed parts, innovative fork crown geometries, and organic frame lines were all possible using 3D printing. Design-for-3D erases all traditional manufacturing limitations, including minimum order quantities, machine lines, and complex assemblies. Furthermore, the weldability and post process properties of 3D printed parts is generally better than cast parts and comparable to machined parts.  Read 3D Print News’ interview with Ti Cycles or designboom’s article for details on this exciting Titanium bicycle project.

I3DMFG EOS M400-4
I3DMFG First With EOS M400.4 + White Paper
I3DMFG Featured On A2Z Manufacturing Magazine Cover
DIRECT METAL LASER SINTERING (DMLS) FOR CAVITIES AND CORES
i3DMFG Metals For Additive Manufacturing
Oregon Welcomes i3D MFG™ 3D Metal Printing
3D Printed “Buzzing” Handlebars on Your Titanium Bike
i3DMFG 3D Printing Services Recreational Industry
i3D MFG™ 3D Prints Titanium Bicycle