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█ Powder-bed-based laser fusing with metals (LaserCUSING ® )

Information about Formnext 2016, Frankfurt

Concept Laser once more demonstrates its role as a leading innovator in 3D metal printing

Machines, software, peripherals, materials – all new from Concept Laser

Sales launch of the new machine architecture M LINE FACTORY

PR 11-2016 Words: 1,032 | Characters: 6,593

document.docx Page 1 of 14


Lichtenfels (Germany), Wednesday, November 15, 2016: Just the announcement of the new machine architecture at formnext powered by TCT 2015 created a stir in the AM sector. This year then saw the commercial launch of the product under the name M LINE FACTORY. For the first time, part production as well as set-up and dismantling processes will take place in two independent machine units so that they can be operated physically separate from one another. This now enables production processes to run in parallel rather than sequentially so that downtimes are considerably reduced and the availability and output quantity of the process chain is thus increased. But the technology leader from Lichtenfels already has a new innovation target in its sights: The machinery and plant manufacturer announced, in a cooperation with Swisslog, a member of the KUKA Group, that it is integrating an automated guided vehicle (AGV) for the automated movement of modules, e.g. powder and components. Visitors were able to admire the first results at Concept Laser's exhibition stand. Further highlights were the premiere of the Mlab cusing 200R in the small machine segment and the presentation of the X LINE PCG in the large machine segment, as an option for the convenient and secure removal of the powder following the production process. As well as the availability of new precious metal alloys, a new product was also unveiled in the area of the QM modules. The new laser power meter, QM Cusing Power, now enables the laser power to be measured directly on the build area.

New M LINE FACTORY is intended to boost 3D metal printingThe long-awaited commercial product launch of the new machine architecture from

Concept Laser, the M LINE FACTORY, took place during the course of formnext

powered by TCT 2016. This heralds a completely new approach in machine architecture




and offers an unprecedented level of automation and innovation.

For the first time, part production as well as set-up and dismantling processes will take

place in two independent machine units so that they can be operated physically

separate from one another and can be combined however you desire. This now enables

production processes to run in parallel rather than sequentially so that downtimes are

considerably reduced and the availability and output quantity of the process chain is

thus increased. The M LINE FACTORY PRD, as the production unit, has a max. build envelope of 400 x

400 x 425 mm³ (x,y,z) and is optionally equipped with 1 to 4 laser sources, each

delivering 400 W or 1,000 W of laser power. The core of the unit is three independent

modules, the dose module, the build module and the overflow module, which can be

individually activated for the first time and therefore do not form one continuous unit.

The individual modules are moved via a tunnel system inside the machine. This means

that, for example when new powder is supplied, the empty powder storage module can

automatically be replaced by a new module immediately without the build process

necessarily needing to be interrupted, as was previously the case. Finished build jobs

can now also be moved out of the machine with the dedicated module and replaced

directly by a new prepared build module so that production operations can be resumed

immediately. Furthermore, a new 2-axis coating process has been implemented and this

permits the return run of the coater to be performed alongside the exposure without the

spatter problems that usually arise in the market today with systems that coat in both

directions. This results in a substantial saving on time during the coating process in

combination with a pursuit for the highest quality. Also under preparation is the

integration of an automated tool changing system, as is the case with CNC machine

technology, which promises flexibility as well as time advantages when setting up the

machine, and further reduces the level of manual intervention by the operator.




The physically separate, autonomous M LINE FACTORY PCG is available as the

processing unit for set-up and disarming processes. This enables “optimum use

windows” right through to the ideal of 24/7 availability of the machine technology. The

new processing unit has an integrated sieving station and powder management. There

is now no need for containers to be used for transportation between the machine and

sieving station. Unpacking, preparations for the next build job and sieving therefore take

place in a self-contained system without the operator coming into contact with the

powder. An automated material flow is another unique selling point. This allows self-

contained modules for transport and material provision to be used.

The associated software suite CL WRX 3.0 includes various user roles with different

authorization levels which enables operator-specific, transparent control and monitoring

of all process operations. In addition, it is an open structure with interfaces to CLS, ERP,

machine technology and automation technology. The intention is that the system should

also be able to integrate remote diagnosis, service monitoring and later also diagnostic

devices. Another advantage is the connectivity with different output media such as

panels, PCs, laptops, or smartphones that an employee can use to stay on top of things.

The modular machine technology of the M LINE FACTORY forms the core of Concept

Laser’s “AM Factory of Tomorrow” concept which also makes provision for upstream

and downstream stages of the production process as well as links to conventional

manufacturing methods. The concept consistently implements the basic idea of

“Industry 4.0” in the form of automation, interlinking, and digitization, and thus permits

the economical series production of additive metal components.

Machinery and plant technology: Premiere of the new Mlab cusing 200R




In addition to its long-standing successful model, the Mlab cusing R, at formnext

powered by TCT Concept Laser has now unveiled its “big brother”, the Mlab cusing 200R. This makes it possible to manufacture even larger parts with much greater

productivity, without the machine losing any of its familiar compactness. The absolute highlights of this new development include:

Maximum productivity thanks to a doubling of the laser power to a level of

200 watts now An expanded build area now covering 100 x 100 mm2 (x,y), which represents an

enlargement of 23%. 54% more build volume overall thanks to a z-axis of an equally enlarged 100

mm makes it possible to manufacture even larger parts Significantly longer machine running time thanks to a larger filter A footprint-optimized design and more accurate part positioning thanks to

clamping system

The intuitive design of the display enables the machine operator to quickly get to grips

with things in maintaining an overview of the process. The provider paid particular

attention to the sieving of the powder. For the Mlab cusing 200R, Concept Laser offers

an inertized sieving station as a stand-alone unit (QM Powder S). QM Powder S enables

independent and automated sieving alongside the production process. The user can

apply a variable number of sieves (1 - 3 units). A three-dimensional sieving motion

enables optimum utilization of the open sieve surface area. Safety was of course right at

the top of the development list for the Mlab cusing 200R: The new model has water-

floodable filter modules and involves physical separation of the process and handling

chambers, which is typical for Concept Laser and ensures maximum safety and easy




handling. The concept of the closed system was a must-have for the Mlab 200R: All

process steps take place under inert gas, shielded from external influences. The whole

process can therefore be called up reliably and with the maximum quality level.

QM modules: Presentation of the laser power meter QM Cusing PowerThe area of quality assurance and monitoring has been one of Concept Laser’s core

areas of expertise for many years. It is no surprise then that our development

department works feverishly to come up with new solutions in this field. For formnext

powered by TCT, the company has now unveiled its latest tool, QM Cusing Power. This

tool now enables the laser power to be measured directly on the build area. The core of

this new concept is a compact measuring device with a digital display. This measuring

device can be used with all machines from Concept Laser (from machine software

version 2.0.3.5). An adapter plate for each type of machine enables easy handling. The

features of QM Cusing Power include:

• Power measurement from 25 – 1000 watts

• Data transmission by Bluetooth and USB

• Evaluation of the measured data via the Primes App

The measurement takes place under inert gas and no additional cooling is required.

Peripherals: Presentation of the X LINE PCG unpacking stationWith the X LINE 2000R, Concept Laser not only offers the machine with the world’s

largest build envelope, but also provides the unpacking station to go with it in the form

of the X LINE PCG. This is recommended as an optional addition to the previous model,

the X Line 1000R. It makes it possible to easily clean components within an inertized




chamber. It is used for removing powder even in highly complex cavities and open

support structures and for returning it to the powder circuit. The X LINE PCG makes it

possible to clean components within the inertized process chamber. The programmed

pivoting about two axes allows the component to be rotated on the platform and reliably

removes the excess powder with a rotary movement. This aspect of automation allows

the manufacturing process to proceed faster and more effectively.

New precious metal alloys for use on Mlab cusing and Mlab cusing RVisitors to formnext powered by TCT also expected new things from Concept Laser on

the material side. For example, various new precious metal alloys for use on Mlab

cusing and Mlab cusing R were presented. Specifically, these were:

• Silver alloy (930 ‰)

• Yellow gold (18 carat, 3N)

• Rose gold (18 carat, 4N)

• Red gold (18 carat, 5N)

• Platinum alloy (950 ‰).

The processing parameters are provided by Concept Laser, the materials themselves

are to be procured from the relevant powder manufacturer.

Print approved – copy requested




Captions ████████████████████████████████████████

Caption 1: The latest machine architecture from Concept Laser: The M LINE FACTORY

is noted for physical separation of the machine units used for part production (M LINE

FACTORY PRD) and the set-up and dismantling processes (M LINE FACTORY PCG).

Sequential operations can now take place in parallel rather than sequentially, which

saves time and costs.

Caption 2: The production unit and processing unit can be combined in any way you

want. Here is an example of a processing unit with two production units.

Caption 3: Several processing units may form a central metal powder preparation unit

Caption 4: The concept of the “AM Factory of Tomorrow”: The “smart factory” is a

flexibly expandable, high-grade automated and centrally controllable meta production

system which is focused fully on the production assignments in hand and thus enables

the economical series production of additive metal components.

Caption 5: Premiere of the Mlab cusing 200R: larger build plate, bigger build volume and

more laser power.

Caption 6: The X LINE PCG packing station: enables powder to be removed even in

highly complex cavities and open support structures and to be returned to the powder

circuit.




Caption 7: New silver and gold precious metal alloys for use on the Mlab cusing and

Mlab cusing R.

Pictures 1-6 courtesy of Concept Laser GmbHPicture 7 courtesy of: AM Finland

Contact ███████████████████████████████████████

Concept Laser GmbHAn der Zeil 8

D-96215 Lichtenfels

Germany

Phone +49 (0) 9571 / 1679-0

Internet: www.concept-laser.de

Press contact:Daniel Hund

Phone: +49 (0) 9571 / 1679-251

E-mail: [email protected]

LaserCUSING® background information ██████████████████████



mailto:[email protected]

http://www.concept-laser.de/


Key word: LaserCUSING®

The patented LaserCUSING® process from Concept Laser is used to create high-

precision mechanically and thermally resilient metallic components. The term

"LaserCUSING®," coined from the C in Concept Laser and the word FUSING, describes

the technology: The fusing process generates components layer-by-layer using 3D-CAD

data.

In this process, fine metal powder is fused locally by a high-energy fiber laser. The

material solidifies after cooling. The contour of the component is created by redirecting

the laser beam using a mirror redirection unit (scanner). The component is built up layer

by layer (with a layer thickness of 15 – 500 μm) by lowering the bottom of the build

chamber, applying more powder and then fusing again.

Source: Concept Laser GmbH

What makes systems from Concept Laser unique is stochastic navigation of the slice

segments (also referred to as "islands") which are processed successively. This

patented process ensures a significant reduction in stress when manufacturing very

large components.




Concept Laser at a glance ██████████████████████████

Concept Laser GmbH from Lichtenfels, Germany is today, unlike almost any other

company, one of the real pioneers and key drivers of powder-bed-based laser fusing

with metals. The technology driver here is the patented LaserCUSING® process, also

referred to as 3D metal printing, which over the course of 15 years has evolved the

additive manufacturing of 3D components from a rapid technology to the stage of

industrial series production.

When Frank Herzog founded Concept Laser GmbH back in 2000 in Lichtenfels, a metal

laser fusing machine was an entirely unknown quantity in the market. How is a 3D

geometry created from metal powder using a laser? What does 3D printing or a digital

process chain mean for the manufacturing of the future?

The answer was industrial machine technology: Concept Laser unveiled the first

machine of this type in 2001 at Euromold in Frankfurt. With 65 patents granted today

and over 120 patent applications, Frank Herzog and his workforce of around 190

employees continue to champion and develop the LaserCUSING® process. The

company caters for the global market for laser fusing machines across all different

sectors from sites in Germany, the USA and China and through a network of more than

35 distribution and service partners.

Concept Laser's high quality standards, expertise in processes, applications and

materials deliver reliable and cost-effective solutions which prove their effectiveness in




everyday production and are primarily aimed at reducing part costs. In addition to

commercial aspects, the process offers a large number of other benefits compared to

conventional methods of production: The components are lighter, the designer has new

freedoms, the topology and geometry are optimized, additional functions can be

integrated, and less raw material is required. What this means is components that were

previously manufactured using machining processes are now being redesigned to fully

exploit the new potential offered by additive manufacturing.

Concept Laser offers a range of small machines (50 x 50 x 80 mm3) right through to the

machine with the world’s largest build envelope (800 x 400 x 500 mm 3). Machines from

Concept Laser that are equipped with multilaser technology are among the fastest,

safest and highest-quality laser fusing machines in the world. Around 650 installed

machines and prestigious references and projects of this Franconian “hidden champion”

around the globe send out a clear message and symbolize an outstanding technology

for the future sealed with the endorsement “Made in Germany”.

For example, today the aerospace industry, automotive industry, medical technology,

dental technology, toolmaking and other sectors focus strategically on 3D metal printing

as the economical and high-quality production strategy of the future that embraces the

notion of "Industry 4.0.”

Prizes & awards ██████████████████████████

2001 Presented with the EuroMold Silver AWARD for the M3 linear

LaserCUSING® machine




2008 Presented with the Bavarian Innovation Prize for the M2 cusing


2012 Presented with the EuroMold Bronze AWARD for the X line 1000R


2014 BAVARIA’S BEST 50 prize-winner

2014 Finalist in the “Large Companies” category for the German Industry

Innovation Prize in the shape of Frank Herzog, Managing Director of

Concept Laser GmbH

Project: “The first 3D-printed titanium component on board the A350 XWB”

2015 The “European CEO of the Year Additive Manufacturing” award was

presented to Frank Herzog, Managing Director of Concept Laser GmbH

2015 Nominated for the German Future Prize – Prize awarded by the German

President for technology and innovation

Project: “3D printing in commercial aircraft engineering – a manufacturing

revolution is taking off” in the shape of Frank Herzog, Managing Director of

Concept Laser GmbH

2015 FOCUS Growth Champion




2016 Winner of the International Additive Manufacturing Award with the QM

Meltpool 3D quality monitoring tool, which was developed in-house

The art of LaserCUSING® by Concept Laser



Documents

PM Concept Laser DE Web view"LaserCUSING®," coined from the C in Concept Laser and the word ... What makes systems from Concept Laser unique is stochastic ... and innovation Project: