First available for EOS machines and in the long-run on AMCM systems
EOS has developed a software solution that could speed up the metal 3D printing process of laser powder bed fusion (LPBF) machines. Named Smart Fusion, the solution automatically adjusts laser power in real-time while eliminating the need for most support structures. This leads to a domino effect throughout other phases of the manufacturing process: less material use, reduced post- processing requirements and lower cost-per-part (CPP) for metal AM applications.
Smart Fusion intuitively detects potential build problems, auto-adjusts the laser power, and eliminates wasted time and resources typically associated with “trial and error” additive manufacturing. Unlike current technologies, Smart Fusion’s real-time capabilities are achieved without adding significant build-time.
According to EOS, customer Beta testing of the Smart Fusion solution has consistently resulted in performance that is two to five times (2x-5x) faster than the leading competitors in the metal AM market. Lower CPP is a primary business driver for the adoption of Smart Fusion. Removing the need for support structures in metal AM makes for a more attractive business case. EOS partnered with several organizations during Smart Fusion’s testing phase where its speed and performance were validated.
How does it look in practice?
Smart Fusion measures the amount of laser power (energy) which is absorbed by the powder bed. A special high-resolution camera overlooking the build chamber monitors each layer’s meltpool emissions via proprietary technology and data is fed back to the laser where it is adjusted. This results in homogeneous energy distribution across the whole build platform thereby reducing stress in the parts and avoiding metal overheating and movement in undesired directions.
At its core, Smart Fusion pairs with EOS’ existing monitoring solutions and employs advanced algorithms to monitor the build layer-by-layer providing for more homogeneous, consistent parts. From a dataflow perspective, EOSPRINT prepares the data which is sent to the 3D printer, Smart Fusion then works with EOSTATE and its Optical Tomography (OT) camera to monitor, measure, and adjust the lasers via EOSYSTEM.
Smart Fusion lists for €27,000/$29,262 (EOS M 290) and €38,000/$41,184 (EOS M 300-4, and EOS M 400-4). The solution requires the Smart Monitoring System package, and is available now for on the following EOS system and materials:
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