ColdMetalFusion combines the advantages of 3D printing with the advantages of Powder Metallurgy to create a 3D printing solution that will enable the transition into industrial 3D printing with a robust process.
The part is built up layer by layer with available laser sintering systems for plastic (SLS). The plastic-binder is melted at low temperature (<80°C). These machines are widely available at affordable prices. No support structures are necessary in the construction process itself, which also enables the parts to be placed freely in the build job.
The finished build job is then de-powdered and cleaned. This process can be automated using air pressure or water jet thanks to the very high green part stability. The rest of the feedstock can be completely reused.
The high strength of the green parts not only helps in the depowdering step, but also allows mechanical (turning, milling, drilling, grinding) post-processing before sintering to the metal part. This offers great advantages, especially for materials that are difficult to machine.
The green parts are debinded in a temperature-controlled solvent to dissolve a part of the binder system. Subsequent distillation enables the solvent to be reused. Overall, solvent debinding is very inexpensive and environmentally friendly compared to other debinding processes.
After the debinding, the sintering step to receive a full metal part takes place. The furnace is slowly heated to sintering temperature while the little remaining plastic-binder (1%-3%) burns without residue already at medium temperatures. At the sintering temperature of the metal, the metal particles fuse together to form a dense solid metal part. The parts shrink evenly, in the example of stainless steel 316L by approximately 13%. The sintered part typically exhibits a density of 97 - 99%.
The sintered metal part can be finished with various post-processing procedures like grinding, polishing, sandblasting and anodizing. Parts can be easily treated with hot isostatic pressing (HIP) or heat treated to achieve desired density and grain structure. You can choose the surface finish which you need to meet your requirements.
You are looking for an external solution provider who supports you with the CMF process and your journey into industrial manufacturing with Additive Manufacturing? Then check out our CMF Production Hubs.
By integrating metal powder into a highly functional binder system, all metals in Powder Metallurgy are available for additive processing.
Low system and operating costs as well as a significantly higher part output result in up to 90% lower part costs.
The high green part stability enables easy post-processing like turning, joining, milling or drilling. This is an enormous advantage, especially for alloys that are difficult to process.
Not processed feedstock can be fully reused.
Processing the feedstock material on SLS systems enables a high part output, which allows real series production for the first time.
In addition to a density of up to 99.9%, ColdMetalFusion metal parts also achieve the same properties as those from other Powder Metallurgical processes.
SLS systems, debinding systems and sintering furnaces are reliable, widespread and easy to maintain. And in addition to the established providers, ColdMetalFusion also runs on SLS entry-level machines.
Developments in the SLS-technology, especially area printing, will bring significant productivity leaps.
