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Additive Manufacturing with Powder Cladding

Selective laser melting (SLM), an additive manufacturing process that uses a high-power laser beam to fuse fine metal powders, is the modern solution for repairing and/or optimizing workpieces of all kinds—but especially for building up and progressively shaping large, multilayer surfaces to create three-dimensional components.

Powder bed printing vs cladding via powder nozzle

SLM includes two popular approaches: three-dimensional powder bed printing and methods in which powder is applied via a nozzle (direct powder deposition). The main difference between them is that direct powder deposition is faster and permits virtually unlimited scalability.

The only constraints on it are how far the system can travel along its axes and the fact that the deposited material usually consists of slightly coarser grains. In the powder nozzle-based SLM process, a laser beam melts and fuses the primary material together with a powder.

Additive Manufacturing of new components

It can be used to create large and in some cases highly complex geometries without any pores or cracks. Another common use is the application of special surfaces to prevent corrosion and wear. Some powders lend themselves to creating extremely hard surfaces that can also be polished to a mirror finish.

Uncomlpcated handling thanks to an innovative quick-change system

O.R. Laser offers customers a flexibly adaptable coaxial coating head. Thanks to an innovative quick-change system, it takes only minutes to install it in any system of the DIODELINE product family.

The coaxial powder nozzle available from O.R. Laser excels with its extreme compactness. All of the required media are specially adapted to the quick-change system, making it extraordinarily easy to retool—time-consuming adjustment of the nozzle is a thing of the past.

Four-axis CNC processing

This technology effectively turns a laser welding system into an extremely powerful setup for additive manufacturing. The coaxial powder nozzle ensures good results regardless of the welding direction. The process is therefore very stable and suitable for automation.

The system can also be expanded by adding a fourth axis. The use of a rotary axis enables full-fledged four-axis CNC processing.

Compatible with ORLAS SUITE

The system is rounded out by an ideal CAM software solution: the ORLAS Suite from O.R. Laser. It lets you import files in a large number of different 3D CAD formats. The software supports STEP, IGES, and STL files, among others. First the software slices the CAD object into multiple layers (known as “solid slicing”).

Then the best strategy can be applied for building the material. A g-code is generated for the chosen strategy and sent to the system. Programming can be done offline. The object is then synthesized completely automatically.


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