JEOL USA blogItems of interest for the JEOL communityhttps://www.jeolusa.com/NEWS-EVENTS/BlogAMS7032: Understanding Aerospace Industry Standards in the Age of Metal Additive Manufacturinghttps://www.jeolusa.com/NEWS-EVENTS/Blog/PostId/108/ams7032-operational-qualification-3d-metal-printing-for-aerospaceAdditive ManufacturingSun, 21 Jan 2024 12:52:37 GMT108Can Metal 3D Printing Be Truly Sustainable?https://www.jeolusa.com/NEWS-EVENTS/Blog/PostId/97/can-metal-3d-printing-be-truly-sustainableAdditive ManufacturingTue, 31 Oct 2023 14:39:55 GMT<h2 id="ific" class="vj-heading text-primary head-style-1">Can Metal 3D Printing Be Truly Sustainable?</h2><div id="i064" class="vj-text text-dark paragraph-style-1">The manufacturing world is undergoing a paradigm shift with the advent of metal 3D printing. As industries strive to adopt sustainable manufacturing practices, the question arises: Can metal 3D printing align with these eco-friendly aspirations? The answer lies in understanding the intricacies of the process, its advantages, and innovative techniques like powder reclamation.<div draggable="true"><br><h1 draggable="true" id="iu8qy" class="vj-heading text-primary head-style-1">Metal 3D Printing: A Sustainable Revolution</h1>Metal 3D printing offers many benefits that can make manufacturing more sustainable. The ability to fabricate complex geometries means that lightweight parts can be produced, reducing material consumption and waste. By eliminating certain prefabrication processes, such as molding, and post-fabrication stages, like machining, metal 3D printing can offer significant economic advantages. Fewer manufacturing steps translate to less material and energy consumption, further bolstering its eco-friendly credentials.</div><br>Moreover, the personalization capabilities of 3D printing technology can lead to reduced waste and heightened efficiency. By using only the required amount of feedstock, 3D printing embodies the potential of zero-waste sustainable design strategies. However, it is important not to overstate the technology's capacity for maximizing feedstock use. It would be untrue to suggest that contemporary additive manufacturing is a zero-waste solution.</div><h1 class="vj-heading text-primary head-style-1" id="iw8j2">Powder Reclamation: The Key to Sustainability</h1><div class="vj-text text-dark paragraph-style-1" id="i48a1">One of the most promising techniques in the realm of metal 3D printing sustainability is powder reclamation. In powder bed fusion, a significant amount of powder remains unused post-printing. Instead of discarding this excess, it can be collected and reused, minimizing material wastage.<br><br><div>However, the process isn't as simple as merely collecting and reusing. The quality of the reclaimed powder is paramount. Factors such as particle size distribution, chemical composition, and potential contamination are pivotal in determining its reusability. Proper monitoring and quality checks ensure the reclaimed powder meets the stringent specifications for subsequent 3D printing tasks.</div></div><h1 class="vj-heading text-primary head-style-1" id="im9no">Challenges and Considerations</h1><div class="vj-text text-dark paragraph-style-1" id="iruij">While metal 3D printing holds immense potential for sustainable manufacturing, it's essential to view it holistically. Post-processing operations, are required to finalize the dimensions and properties of metal printed parts. The part's design, size, material, and the volume of parts produced are all variables that influence the sustainability quotient.<br><br><div>At Jeol, we believe in the transformative power of <a href="https://www.jeolusa.com/PRODUCTS/Additive-Manufacturing-3D-Printer" id="iq8c6" class="link">metal 3D printing</a>. Its potential to revolutionize the manufacturing landscape while adhering to sustainable practices is undeniable. However, achieving true sustainability requires a comprehensive understanding of the entire process, from printing to post-processing. As we continue to innovate and refine our techniques, we invite the scientific community to explore our additive manufacturing solutions. Discover how we're shaping the future of sustainable manufacturing. Together, let's forge a greener future. </div><div><br></div></div><div id="inard" class="spacer"></div>97JEOL Introduces New EBM 3D Metal Printerhttps://www.jeolusa.com/NEWS-EVENTS/Blog/PostId/89/ebm-metal-3d-printer-introAdditive ManufacturingWed, 13 Sep 2023 00:23:56 GMT89Overcoming Key Challenges In Metal 3D Printinghttps://www.jeolusa.com/NEWS-EVENTS/Blog/PostId/56/overcoming-key-challenges-in-metal-3d-printingAdditive ManufacturingTue, 24 Jan 2023 16:20:47 GMT<div class="vj-text text-dark paragraph-style-1" id="i4se">Metal 3D printing is a unique additive manufacturing (AM) technology that has developed significantly over the last two decades. When complex pieces of intricate details need printing, AM technology is the ideal solution. It produces metal components layer by layer via melting, sintering or welding, and this process offers benefits such as lightweight but strong components. Although this technology has provided boundless opportunities for metal printing, a few drawbacks still need to be addressed. This blog post will look at how to overcome some of those critical challenges.</div><h2 class="vj-heading head-style-1 text-dark" id="insnm">What are the Key Challenges in Metal 3D Printing?</h2><div class="vj-text text-dark paragraph-style-1" id="imgi">Metal 3D printing provides many benefits to companies that manufacture metal components compared to traditional manufacturing methods. It is used not only for complex pieces but also for applications requiring lightweight metal parts still high in strength. However, despite the numerous advantages, a few key issues need to be addressed with the 3D printing process. This section will cover those issues and offer solutions to overcome them.</div><h3 class="vj-heading head-style-1 text-dark" id="i0tq7">Cracking</h3><div class="vj-text text-dark paragraph-style-1" id="i81nf">When a melted metal begins solidifying, specific errors can occur, leading the metal to crack. If a metal powder has not melted fully or remelts below surface level, this results in delamination, which causes cracking. Another issue is that when the metal cools down, contractions can happen. These contractions can deform a metal, which results in cracking.</div><div class="vj-text text-dark paragraph-style-1" id="iore8"><b>Solution:</b> You have a few options to prevent metal components from cracking. The first is to use a heated bed and set it to the correct temperature and the second option is to set the printer to a slightly slower printing speed. Additionally, ensure the bed is thoroughly cleaned after each use to remove any dirt, which can lead to warping.</div><h3 class="vj-heading head-style-1 text-dark" id="ipiqx">Density</h3><div class="vj-text text-dark paragraph-style-1" id="ihl7b">If there are high porosity levels, as explained below, this can lead to low-density levels. The issue with low density is that it leads to cracking and fatigue, thus compromising the component's strength.</div><div class="vj-text text-dark paragraph-style-1" id="iwwv7"><b>Solution:</b> Unfortunately, some trial and error may be needed to solve any density issues. This is because multiple variables can cause density problems. Using high-quality metal powder is the first step in limiting density issues, and then the parameters of the material must be considered, such as particle distribution, shape and size.</div><h3 class="vj-heading head-style-1 text-dark" id="i5ekj">Porosity</h3><div class="vj-text text-dark paragraph-style-1" id="ih8oc">High porosity is a common problem in 3D metal printing, as pores in the material can develop due to the powder used in the printing process. Pores are tiny holes that minimize the material's density and cause problems such as cracking and fatigue. An additional cause is the amount of energy used during the printing process, as both too much and too little can result in pores in the material.</div><div class="vj-text text-dark paragraph-style-1" id="ij7yy"><b>Solution:</b> As mentioned above, the quality of the metal powder is key to reducing this problem. Using high-quality raw materials should reduce the risk of pores. Another possible solution is to tune your printer to meet the required parameters of the metal.</div><h3 class="vj-heading head-style-1 text-dark" id="i59ae">Residual Stress</h3><div class="vj-text text-dark paragraph-style-1" id="iyuz6">Residual stress is one of the most common issues with metal 3D printing and can impact the integrity of the product. It is caused by the heating and cooling cycle that takes place during printing and results in components cracking or warping.</div><div class="vj-text text-dark paragraph-style-1" id="i5kwj"><b>Solution:</b> Residual stress can also be minimized by heating the printing bed correctly before and during printing, and estimating the required parameters of the metal during the printing process.</div><div class="vj-text text-dark paragraph-style-1" id="ikszl">Other issues that companies mentioned included the availability and the cost of materials, manufacturing costs, surface finish and technology limitations.</div><h2 class="vj-heading head-style-1 text-dark" id="irt1p">JEOL and Metal 3D Printing</h2><div class="vj-text text-dark paragraph-style-1" id="ig78">JEOL has developed an electron beam metal AM machine that utilizes our unique additive manufacturing technology to enhance 3D metal printing. Our <a href="/PRODUCTS/Additive-Manufacturing-3D-Printer" id="inj4z" class="link">JAM-5200EBM</a> was developed through decades of experience from the JEOL team, specializing in advanced electron optics and control technology. Our technology reduces the risks of the problems outlined above because the laser beam method in our metal 3d printer offers higher power and density than other market options.</div><div class="vj-text text-dark paragraph-style-1" id="icpc">For more information on metal 3D printing and how our AM machine overcomes the critical issues mentioned above, contact us today and speak to one of our experts.</div>56Which Metals can be 3D Printed?https://www.jeolusa.com/NEWS-EVENTS/Blog/PostId/53/which-metals-can-be-3d-printedAdditive ManufacturingTue, 22 Nov 2022 12:39:08 GMT53What is 3D Metal Printing and How Does it Work?https://www.jeolusa.com/NEWS-EVENTS/Blog/PostId/50/what-is-3d-metal-printing-and-how-does-it-workAdditive ManufacturingWed, 02 Nov 2022 23:45:52 GMT<div class="vj-text text-dark paragraph-style-1" id="icv5">3D metal printing is a term that is used to cover several processes in which metal objects are produced by technology. Simply put, a highly focused beam of energy is used to scan and melt metal powder particles, which bonds them together to manufacture a component layer by layer. Although machine manufacturing is still the preferred method for producing metal components, a more specialist approach is often required, which brings us to 3D metal printing. This post will aim to cover the basics of what 3D metal printing is and how it works.</div><h2 class="vj-heading head-style-1 text-dark" id="igkus">What is 3D Metal Printing?</h2><div class="vj-text text-dark paragraph-style-1" id="i8bs">The term 3D metal printing covers several technologies used for printing metal. The standard process involves melting or sintering metal powders, although some powders can be combined with additional material. Typical metals and metal alloys used in powder form are aluminum, copper, nickel, steel, stainless steel, titanium, tungsten, and precious metals such as gold, palladium, platinum, and silver.</div><div class="vj-text text-dark paragraph-style-1" id="iqyg">There are a few main metal printing types, such as selective laser melting (SLM), direct metal laser sintering (DMLS), electron beam melting (EBM), and some additional methods. However, some of the others have limited applications. Therefore, we won’t cover them in this article.</div><h3 class="vj-heading head-style-1 text-dark" id="ixnzv">Selective Laser Melting (SLM)</h3><div class="vj-text text-dark paragraph-style-1" id="iqli">One of the primary metal printing methods involves melting the material with a laser in an inert gas environment. The process is repeated layer by layer to create similar components and is often used for manufacturing parts in the aerospace, automotive and medical industries.</div><h3 class="vj-heading head-style-1 text-dark" id="i6w5i">Direct Metal Laser Sintering (DMLS)</h3><div class="vj-text text-dark paragraph-style-1" id="iqzn">As the name suggests, this method sinters metal powder with a laser and forms an object layer by layer. DMLS is typically used for prototyping and producing finished components such as medical devices.</div><h3 class="vj-heading head-style-1 text-dark" id="ig3ai">Electron Beam Melting (EBM)</h3><div class="vj-text text-dark paragraph-style-1" id="ivyd">EBM is a similar process to SLM, with the critical difference being that an electron beam is used instead of a laser. EBM is frequently used to produce components from nickel and titanium alloys, is suitable for the aerospace industry.</div><h2 class="vj-heading head-style-1 text-dark" id="i4ohy">JEOL: 3D Printing</h2><div class="vj-text text-dark paragraph-style-1" id="i8nq">JEOL is making advancements in the world of 3D printing with our unique additive manufacturing technology and our electron beam metal AM machine. Our technology enhances additive manufacturing so lighter manufactured components can be produced more cleanly and efficiently for use in the aerospace, medical, and energy industries.</div><div class="vj-text text-dark paragraph-style-1" id="iwm4">The JEOL electron beam metal AM machine, the <a href="/PRODUCTS/Additive-Manufacturing-3D-Printer" id="i4bth" class="link">JAM-5200EBM</a>, provides several benefits for additive manufacturing. These advantages stem from JEOL’s decades of experience developing advanced electron optics technology and our current position as the market leader for electron microscopy instruments. </div><h3 class="vj-heading head-style-1 text-dark" id="isjek">JAM-5200EBM</h3><div class="vj-text text-dark paragraph-style-1" id="ih7i">The key features of this instrument include automatic electron beam correction, long-life cathode and a remote monitoring system. The cathode will run for over 1,500 hours, allowing total system uptime to be improved and manufacturing quality to remain high. The machine operates in a clean and helium-free environment. Other <a href="/NEWS-EVENTS/Press-Releases/jeol-leverages-50-years-of-e-beam-expertise-to-bring-new-metal-additive-manufacturing-system-to-the-americas" id="iqzrr" class="link">features and benefits</a> include the following:</div><h4 class="vj-heading head-style-1 text-dark" id="igfni">Automatic Correction</h4><div class="vj-text text-dark paragraph-style-1" id="ibsu2">The automatic correction and alignment function was developed in-house by JEOL and will ensure the focus and spot shape of the electron beam are precise according to the irradiation position.</div><h4 class="vj-heading head-style-1 text-dark" id="i7whl">Eco-Friendly</h4><div class="vj-text text-dark paragraph-style-1" id="ib97m">The AM machine is helium-free, and the ‘e-shield’ component eliminates any smoke that may arise during the manufacturing process. Additionally, the machine can produce multiple parts in one run, reducing waste and run time for single products.</div><h4 class="vj-heading head-style-1 text-dark" id="ite9d">Remote Monitoring</h4><div class="vj-text text-dark paragraph-style-1" id="iaapd">It is possible to monitor the manufacturing status and the current system conditions remotely, allowing for efficient updates and reducing the time personnel would spend going to and from the machine. An alarm function is also available.</div><div class="vj-text text-dark paragraph-style-1" id="icjwa">Contact us today for more information about our JAM-5200EBM or to request a virtual demonstration.</div>50JEOL and Additive Manufacturing – why JEOL developed a new 3D Printerhttps://www.jeolusa.com/NEWS-EVENTS/Blog/PostId/47/why-jeol-additive-manufacturing-3d-printerAdditive ManufacturingTue, 04 Oct 2022 23:18:40 GMT47