ADDITIVE MANUFACTURING
Below and right : Smithstown ’ s additively-manufactured portfolio .
TRUMPF ’ s AM portfolio
TRUMPF offers both relevant laser technologies for additive manufacturing from a single source : laser metal fusion ( LMF ) and laser metal deposition ( LMD ). New innovations to the range include green laser technology for 3D printing of copper and other precious metals .
TRUMPF also strengthened its Additive Manufacturing ( AM ) division by taking over the joint venture TRUMPF SISMA S . R . L . completely from its Italian partner , SISMA S . p . A . It will continue SISMA ’ s LMF ( Laser Metal Fusion ) business in the industrial , dental and medical markets .
The aim was to provide an additive support role for Smithstown ’ s medical device customers , specifically for R & D work .
“ We looked at many potential machines , before designing our own benchmark and sending it to suppliers of interest ,” said Kevin Kelly , a Smithstown manufacturing engineer . “ It was the quality of the benchmark produced by TRUMPF , using its TruPrint 2000 , which caught our attention . In addition , the volume of the machine was perfect for our needs and the price was competitive .”
Installed at the end of 2020 , Smithstown is using its new TruPrint 2000 to produce printed parts from metal . The company ’ s new Additive Centre also houses a machine for printing polymer components .
“ Additive manufacturing is ideal for medical work because of the complex geometries involved ,” explained Kevin Kelly . “ Without 3D printing , several processes would be required , taking many hours . Additive manufacturing also offers the potential for individual customisation , which has obvious benefits for products such as implants .”
Prototypes and samples
Since installation , the machine has been busy producing prototypes and samples for medical device customers in 17-4 and 316 stainless steel .
“ In the medical sector , it can take years to move from the design and test stage to validated production , but we ’ re now in a position to help expedite this process and bring customer ideas to life ,” outlined Kelly . “ Upon reaching the production phase of current projects , we could well need several 3D printing systems so that we can dedicate machines to a single material . We will not hesitate to invest in more machines if the demand is there .”
With its small 55 µ m diameter laser beam , the TruPrint 2000 provides a high-quality printing result . Two TRUMPF 300W fibre lasers deliver high productivity over the entire cylindrical build volume of 200mm diameter x 200mm high . Among notable options that help to ensure high quality standards is melt pool monitoring . With this function , deviations in the laser metal fusion process are detectable early via sensors , and critical areas of the component can be visualised . Users can also monitor all weld pools in parallel .
TRUMPF development engineers reduced the TruPrint 2000 laser ’ s focal diameter to 55 micrometers to print components with smoother surfaces , enhanced quality and intricate grid structures . The TruPrint 2000 prints parts out of titanium , a material that figures prominently in medical devices .
“ Users enjoy the benefits of automated powder bed and melt pool quality monitoring . Another benefit is an end-to-end documentation trail that corroborates the quality of the printing process . This is a key prerequisite for the additive manufacturing of medical devices ,” TRUMPF told ISMR .
An eye on the future
carries certifications that include ISO9001 ( quality ), ISO13485 ( medical devices ) and ISO14001 ( environmental ) – has recently secured several new projects that are driving the need for more staff recruitment . Alongside its investment in the latest manufacturing technologies , ongoing growth is assured at this business .
“ We are really happy with the quality and build speed of the TruPrint 2000 , which is backed-up with good support from TRUMPF who have listened to our needs throughout ,” concluded King . “ As a result , we have not experienced any unexpected issues whatsoever , which is impressive considering
WATCH that this is our first venture into additive manufacturing .” n
Moving forward , Smithstown ’ s business strategy is to focus more on high-volume precision components , rather than simply
www . trumpf . com tooling and small-batch parts . “ Some of our competitors have 3D printers ,
https :// sle . ie but the TruPrint 2000 definitely gives us an edge ,” said Kelly . “ We also have a dedicated team of experts who can design parts specifically to leverage the benefits of additive manufacturing , helping to minimise costs without compromising quality . Designing a part for additive is quite different to designing a part for traditional machining .”
Smithstown – which The TruPrint 2000 features built-in powder removal capability .
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ISMR April 2022 | sheetmetalplus . com | 23