• January 19, 2021
  • Register
  • Sign in
    • Forgot Password ?
    OR
    • Sign in
  • FAQ
  • Contact
  • About us
www.cnctimes.com logo
  • Editorials
    • NEWS
    • CASE STUDIES
    • INTERVIEWS
    • SUCCESS STORY
    • PRODUCT SHOWCASE
    • TECHNICAL ARTICLES
    • BLOGS
    • VIDEOS
    • NEWSLETTERS
  • Forum
  • EVENTS
  • INVENTORY
    • INVENTORY LISTINGS
    • AUCTION LISTINGS
    • WANTED LISTINGS
  • BUSINESS LEADS
    • BUYERS
    • MANUFACTURERS
    • DEALERS
  • SHOWROOM
  • JOBS
  • Register
  • Sign in
  • Contact
  • Advertise
  • Feedback

Information

Please login to give the feedback.

Information

Please login to give the feedback.

  1. Home
  2. Case Studies
  3. Venturing into metal additive manufacturing

Venturing into metal additive manufacturing

04 June, 2019
  • Tweet
  • share via email
Your comment has been posted.
We have sent you a verification email. To verify, just follow the link in the message.
Some technical error. Please try again.

The market for specialist metal additive manufacturing (AM) services is rapidly evolving as more and more companies realise the advantages which metal additive manufacturing offers over more traditional design and manufacturing techniques. 

3D Metalforge, a nascent additive manufacturer, set-out to provide customers with a complete end-to-end 3D metal printing service capable of producing in volume, intricate, high-quality end-use metal parts. Its choice of metal additive machinery would be a critical factor to its success. The systems it purchased needed to be well-supported globally and Industry 4.0-ready. They had to provide the quality, flexibility and reliability that the new venture demanded. 

Today, 3D Metalforge's ISO-certified production facility is used by industrial customers operating in the marine, oil and gas, precision engineering and general manufacturing sectors. The kinds of advanced metal printed parts it produces include impellers, antenna mounts, lifting hooks and swivel joints.

A highly specialised company, 3D Metalforge provides its customers with a complete end-to-end metal AM service, comprising consulting and diagnostics, part design or re-design, high-quality part printing and post-production (heat treatment, sawing, bead blasting, polishing and finishing). 

Background

Metal AM company 3D Metalforge was founded in Singapore at the end of 2016. A sister company of 3D Matters, one of South East Asia's fast-growing additive manufacturers, the company was established in response to rapidly increasing demand for high accuracy three-dimensional metal part manufacturing.

Industrial customer requirements for 3D metal printing services are changing dramatically in the region, from a predominance of short-run prototyping and one-off modelmaking to more volume production of end-use parts.

This demanded a dedicated new production facility with a significant investment in metal additive machinery.

Matthew Waterhouse, CEO of 3D Metalforge explains, “Customers moved very quickly from a position of not really knowing that certain parts could actually be printed in metal, to the point where they understood the advantages of metal additive manufacturing over traditional manufacturing and the part complexities and high quality that could be achieved.”

 

 

Challenge

As an all-new venture in a rapidly evolving manufacturing sector, 3D Metalforge sets stringent selection criteria for its metal additive system purchases. Faced with a wide range of alternatives, the company needed to be certain that the capital investments it made would provide its customers with the service they needed today and well into the future. Criteria included:

  • Additive production samples needed to demonstrate high-quality
    and the ability to produce a wide range of fine line, high complexity parts.
  • Technical support from the manufacturer needed to be locally-based, for both pre- and post-sale phases.
  • System reliability is paramount for end-use part production. It needed to be proven.
  • The system needed to be easy to use, with a minimal learning curve.

The system manufacturer will also need to show clear knowledge and understanding of manufacturing and typical 3D Metalforge operations.

3D Metalforge is also very mindful of emerging Industry 4.0 trends. The metal additive systems they purchased would also need to be capable of supporting the key principles of the ‘fourth industrial revolution', including data transparency, connectivity and human-machine interface.

 

Waterhouse explains, “We see metal additive manufacturing as an integral part of Industry 4.0, something that's at the forefront of future manufacturing change. Forward-thinking companies in Singapore and the rest of Asia are fully embracing the Industry 4.0 concept and we needed to reflect that in our decision-making.” 

Solution

Hardware and support

One of the first systems to meet 3D Metalforge's selection criteria was Renishaw's small footprint AM 400 additive manufacturing system. With a 250 mm x 250 mm x 300 mm build volume, the system is equipped with a 400W laser system with a beam diameter of just 70 μm. Its human-machine interface is highly graphical and intuitive in nature.

Following an ‘open parameter' ethos, the AM 400 provides 3D Metalforge with the freedom to optimise machine data settings to suit the metal powder being processed and specific target geometry. The system's inert gas atmosphere is class-leading and its SafeChange™ filter handling system minimises contact with powders and process emissions.

Mr. Waterhouse said, “Renishaw was already well known to us through its precision measurement technologies. Importantly, Renishaw clearly understood manufacturing, it knew about material setup, calibration and how we wanted our new facility to operate.”

“From the outset, we were immediately impressed by the very high quality of the production samples presented. Our belief is that metal 3D printing and traditional machining processes should complement one another, and we could see how the AM 400 could help make post-production processing easier.” 

Software

For the vast majority of the work undertaken with the Renishaw AM 400 additive manufacturing system, 3D Metalforge uses Solid Works software for initial 3D CAD design, along with Autodesk to work on part printability when required.

Renishaw's QuantAM build preparation software is then used to optimise support structures for aligning the part within the build volume and setting up the final print file.

3D Metalforge also uses Renishaw's InfiniAM Central, software specifically designed for remote process monitoring of additive manufacturing systems. Providing near real-time insight into live additive manufacturing builds and access to historic build data, it displays system information in a highly graphical form enabling intuitive in-depth analysis. 

Results

During the 18 months since commissioning, the AM 400 additive manufacturing system has become 3D Metalforge's busiest and most utilised metal 3D printer, with machine up-time, accuracy and reliability cited as extremely good by Waterhouse.

He shares an example on how 3D Metalforge provided a complete end-to-end metal 3D printing service to a technology equipment company:
"The equipment company looked for a way to optimise its part, a metal tray, and improved its in-product performance. Unable to achieve desired design goals using traditional manufacturing techniques, the company approached 3D Metalforge for an alternative metal printed solution."

Since the original part design wasn't optimised for AM, it was first re-designed. 3D Metalforge introduced lattice structures to reduce weight and new shaping to enhance part alignment. A few prototypes were produced and tested within the end-product assembly before finalising the part design. 

A few hundred of these intricate metal parts have so far been produced using the AM 400 system for a quality control pass rate of 100%. The AM design has reduced the weight whilst enhancing its performance.

For the future, 3D Metalforge foresees a lot more work taking place in the realm of standards and certification for additive manufacturing, and the production of even more advanced industry specific parts as a result. As more and more sectors embrace AM it also expects to see the range of specialised metal powders increasing.

3D Metalforge expects to continue to expand the range of systems it operates, to support a wider mix of part sizes and a wider range of metal powders. The company is planning to open further factories in high growth Asian markets and is currently expanding its presence and solution offerings in the USA, which it identifies as one of the largest markets for its unique brand of metal AM services. 

 

  • Follow @CNCTimes

Captcha is required.
Sorry Captcha Unsuccessful!!

Latest Case Studies

  • 03 August, 2020

    Automated production line for FFP3 filters up and running after just eleven days with the help of SCHUNK

  • 07 January, 2020

    In-house metrology increases machine tool uptime by 20%

  • 16 December, 2019

    Lifting Devices Provider Cyrus Designs 20% Faster with ZW3D

  • 16 December, 2019

    Khodiyar Industries Chose ZW3D to Speed up Packaging Machine Production

  • 16 December, 2019

    In-house metrology increases machine tool uptime by 20%

  • 19 August, 2019

    Automated workpiece set-up boosts forestry equipment manufacture

  • 30 July, 2019

    Laser interferometer error-proofs linear scale calibration

  • 08 July, 2019

    Improving speed and reducing cost with Renishaw additive manufacturing

  • 13 May, 2019

    Renishaw Equatorâ„¢ gauge enables production growth at major aerospace manufacturer

  • 08 April, 2019

    50% faster turbine blade inspection

  • 08 April, 2019

    FARO® QuantumS ScanArm: Executing the Work of Two Measurement Devices

  • 04 April, 2019

    Laser interferometry assures spherical lens quality

  • 01 April, 2019

    Why The World's Third Largest Motorcycle Manufacturer Opted For Universal Robots

  • 29 March, 2019

    Aerospace: Sogeti - Additive Manufacturing for the new A350 XWB

  • 28 March, 2019

    Overcome the Ongoing Challenges of Long-Reach Machining

  • 12 March, 2019

    BLUM touch probes on Strama-MPS

  • 11 March, 2019

    INTECH DMLS Achieves 27% Weight Reduction in 3D Printed Satellite Component using Altair InspireTM and OptiStructTM

  • 14 February, 2019

    Zoom Technologies Chooses CADbro, a powerful 3D CAD Viewer, to Accelerate Customized Mold Production

  • 25 December, 2018

    Renishaw and Hartford combine to deliver intelligent, ‘smart factory’ solutions

  • 18 December, 2018

    Measurement of free-form surfaces made easy

  • 14 December, 2018

    A Measuring Tool System That Modified the Concept of Machinery

Previous Next

Related Case Studies

  • 16 June, 2020

    Equator gauging system leads to 30% increase in manufacturing capacity

    Category: Metrology
  • 20 December, 2017

    Renishaw AM technology helps Swinburne electric car to best-ever Formula SAE result

    Category: Additive Manufacturing - RP
  • 24 October, 2017

    570,000 individual measurement values per driveshaft

    Category: Metrology
  • 24 October, 2017

    Renishaw technology helps Breton calibrate its in-house machinery and control the quality of its output

    Category: Metrology
  • 24 October, 2017

    Ballbar diagnostics aid airframe manufacture

    Category: Metrology
  • 26 September, 2017

    Making time for Holthinrichs Watches: Renishaw Case Study

    Category: Metrology
  • 07 August, 2017

    Exchanging metal 3D printing solutions with HiETA

    Category: Additive Manufacturing - RP
  • 29 June, 2017

    KOMET® GROUP innovates cutting tools using metal 3D printing technology

    Category: Additive Manufacturing - RP

News

  • 18 January, 2021

    Nikon Metrology's new Detector Evaluation Package in accordance with ASTM E2737

    Category: Metrology
  • 12 January, 2021

    FARO® ZONE 3D 2021 SOFTWARE RELEASED FOR OPTIMAL FORENSIC SCENE DOCUMENTATION

    Category: Metrology
  • 05 January, 2021

    FARO® LAUNCHES LATEST VANTAGE LASER TRACKER 6DOF PROBE

    Category: Metrology
  • 29 December, 2020

    Change of Accuracy Indication for Depth Gage and Height Gage

    Category: Metrology
  • 22 December, 2020

    TAKAM uses XK10 to ensure assembly accuracy of machine tools :XK10 alignment laser system

    Category: Metrology
  • 15 December, 2020

    Dedicated PolyWorks interface for Hexagon structured light scanners

    Category: Metrology
  • 08 December, 2020

    Siemens expands software ecosystem for industrial additive manufacturing

    Category: Additive Manufacturing - RP
  • 08 December, 2020

    VAD Instrument chooses Renishaw’s UHV optical encoders for motion platforms

    Category: Metrology
  • 01 December, 2020

    Nikon Metrology's new Detector Evaluation Package in accordance with ASTM E2737 uniquely offers automated analysis of image data

    Category: Metrology
  • 24 November, 2020

    New release of CARTO software provides unlimited measurement range for XM-60 multi-axis calibrator

    Category: Metrology
  • 17 November, 2020

    OGP Celebrates Milestone 75th anniversery at the forefront of Dimensional Metrology

    Category: Metrology
  • 17 November, 2020

    New QUANTiCâ„¢ encoder with analogue output

    Category: Metrology

Interviews

  • 25 May, 2020

    Short interview with Peter Mösle, Head of Sales of the Measuring Machines business division at Blum-Novotest

    Category: Metrology
  • 30 April, 2019

    CNCTimes in conversation with, Ankit Sahu, Director, Objectify Technologies Pvt. Ltd.

    Category: Additive Manufacturing - RP
  • 19 February, 2019

    CNCTimes in conversation with, Mr Frederick Mason, Sr. V.P. Marketing, Quality Vision International INC

    Category: Metrology
  • 28 May, 2018

    Our consistent goal is to continually improve the quality, performance and reliability of our products: Revware Inc

    Category: Metrology
  • 24 January, 2017

    Blum-Novotest to focus mainly on visibility during IMTEX 2017: BV Shyam

    Category: Metrology
  • 25 November, 2016

    Indians are investing in high-quality devices for the long-term: Harkiran Sandhu

    Category: Metrology
  • 14 September, 2016

    India has and will always welcome new technologies: Beng Chieh Quah

    Category: Metrology
  • 09 February, 2016

    It’s tough selling in India, price a major factor: Anup Verma

    Category: Metrology
  • 20 February, 2015

    Reliability and respectability is Hexagon Metrology’s motto

    Category: Metrology
  • 04 January, 2016

    ‘Divide By Zero committed to take 3D Printing to infinite possibilities’

    Category: Additive Manufacturing - RP

Product Showcase

  • 06 July, 2019

    KEYENCE Announces New 4K Ultra-High Accuracy Microscope

    Category: Metrology
  • 14 May, 2019

    Versatile quick-change system for handling weights up to 50 kg

    Category: Metrology
  • 15 April, 2019

    3D Goes Long-Range With the First Scanning Laser Tracker

    Category: Metrology
  • 10 April, 2019

    LASERTEC 12 SLM – four-times more accurate than the industry standard!

    Category: Additive Manufacturing - RP
  • 25 March, 2019

    EOS M 300-4

    Category: Additive Manufacturing - RP
  • 11 October, 2018

    Gas-tight blowers for additive manufacturing methods from Becker

    Category: Additive Manufacturing - RP
  • 09 April, 2018

    OMRON Microscan Debuts Duo of Best-In-Class Barcode Readers

    Category: Metrology
  • 04 March, 2017

    Contour Measuring Systems CONTRACER CV-4500 Series from Mitutoyo

    Category: Metrology
  • 04 March, 2017

    3D X-RAY MEASUREMENTS FOR QUALITY ASSURANCE ZEISS METROTOM

    Category: Metrology
  • 24 June, 2016

    Unique portable roughness tester from Mahr

    Category: Metrology
  • 16 June, 2016

    Creaform tackles automated inspection with new Metrascan 3d r-series

    Category: Metrology
  • 26 November, 2015

    New software extends QC20-W ballbar capability for time based data capture

    Category: Metrology

Technical Articles

  • 28 January, 2020

    The Additive Update: Wilson Tools

    Category: Additive Manufacturing - RP
  • 29 September, 2016

    Better accuracy, speed in on-site data acquisition for Building Information Modeling

    Category: Metrology
  • 29 August, 2016

    Price, selection of application-oriented solutions affects machine tool sales in India

    Category: Additive Manufacturing - RP
  • 03 February, 2016

    5 Ways that 3D Measurement Improves Quality & Productivity for Automotive Industry

    Category: Metrology
  • 20 September, 2013

    The M & H IRP25.50 – modular and future-ready with the Dual Probe Technology

    Category: Metrology

Blogs

  • 19 April, 2019

    Additive Manufacturing: a big leap in production

    Category: Additive Manufacturing - RP
  • 30 June, 2018

    Global Dimensioning & Tolerancing

    Category: Metrology
  • 25 May, 2016

    The Concept of Measurement Accuracy

    Category: Metrology

Videos

  • 22nd September, 2020

    Import of worn tools from the NCSIMUL | Tool base

    Category: Metrology
  • 07th September, 2020

    EDGECAM - Cad update

    Category: Metrology
  • 26th August, 2020

    WORKXPLORE – Model Comparison Function

    Category: Metrology
  • 06th August, 2020

    Radtube - Driving Dedicated Tube Cutting Machines As Well As The Rotary Axis On Flat Bed Lasers

    Category: Metrology
  • 07th April, 2020

    Mr. Ravi Moolya, CEO, SPERONI INDIA Pvt. Ltd : COVID 19

    Category: Metrology
  • 07th April, 2020

    Mr.Shekhar Erande, Director, Sigmatek Systems India Pvt. Ltd : COVID 19

    Category: Metrology
  • 20th April, 2019

    Powering the future of metal additive manufacturing at Sandvik

    Category: Additive Manufacturing - RP
  • 10th April, 2019

    INTEGREX i-400S AM : Integration of additive manufacturing and multi-tasking

    Category: Additive Manufacturing - RP
  • 03rd April, 2019

    Additive and Subtractive in One Machine with Mazak

    Category: Additive Manufacturing - RP
  • 14th March, 2019

    Video Testimonial of Mr. Shreyansh B Hippargi, Managing Director at QVI India Pvt. Ltd

    Category: Metrology
  • 02nd February, 2019

    ASI Datamyte at IMTEX 2019

    Category: CMM
  • 30th January, 2019

    Polyworks Software India Pvt Ltd at IMTEX 2019

    Category: Metrology

Inventory

  • 11 February, 2019

    EOS M290 DMLS 3D Printer

    Category: Additive Manufacturing - RP
  • 10 August, 2017

    DEA 'Swift' Co-Ordinate Measuring Machine

    Category: Metrology
  • 10 August, 2017

    DEA 'Pioneer 081206' Co-Ordinate Measuring Machine

    Category: Metrology

Showroom

  • 15 May, 2017

    600 Data Collector

    Category: Metrology
  • 15 May, 2017

    LightStar Torque Wrench

    Category: Metrology

TESTIMONIALS VIEW MORE

We would like to express our sincere appreciation for your service to us.You have provided us best marketing platform through CNCTimes. We look forward to extending our contract with you for years to ...

Mr.Adil Atar, Ass.Mng.Technical Sales & Service: Precision Machinekraft

Dedication and determination is key to success and CNC Times team is evident to it - FARO Business Technologies (I) Pvt Ltd

Ms. Amrita Gokhale , FARO Business Technologies

Seminar was really very good, please let us know about future seminars. we would like to attend the seminar on "Machining of the material above 60 HRc like titanum"

Roshan Deshmukh, Design Engineer - Ashvini Magnets Private Limited

FOLLOW US

TECHNOLOGY FOCUS

    Machine Tools

    • CNC Lathe
    • Boring Machines
    • Drilling Machines
    • Spark Erosion
    • Wire Cut
    • Vertical Machining Centers - VMC
    • Horizontal Machining Centers - HMC
    • Grinding Machines
    • Gear Cutting Machines
    • Additive Manufacturing - RP
    • Multi-Axis Machines
    • Multi-Tasking Machines
    • Welding Machines
    • Presses
    • Laser Cutting
    • Others
    • IIoT

    Metrology

    • CMM
    • VMM ( Vision Measuring Machines )
    • PCMM ( Portable CMM )
    • Measuring Instruments
    • Probing Technology
    • 3D Scanners
    • Roundness Measurement
    • Surface Roughness Measurement
    • Contour Measuring Machines
    • Others

    Accessories

    • Workholding
    • Toolholders
    • Spindles
    • Coolants
    • Others

    Software

    • CAD
    • CAM
    • CAE
    • ERP
    • Inspection Software
    • Reverse Engineering Software
    • MES
    • Others

    Mechatronics

    • Robotics
    • Automation
    • CNC Controllers
    • Others

    Cutting Tools

    • Turning Tools
    • Milling Tools
    • Grinding Wheels
    • Drilling
    • Others

INDUSTRY VERTICALS

  • General
  • Automotive
  • Aerospace
  • Healthcare
  • Healthcare Engineering
  • FMCG
  • Consumer Durable
  • Defence
  • Electronics
  • Oil & Gas
  • Heritage
  • Heavy Engineering
  • Die & Mold
  • Plastic
  • Footwear
  • Jobshop

POLICIES

  • Payment Policy
  • Terms of Use

PROFILE

  • About us
© 2021 www.cnctimes.com
Developed & Maintained by CNCTimes.com