Desktop Metal aligns 4140 low-alloy steel with high-volume additive manufacturing of end-use parts in the production system-Green Car Conference

2021-12-16 08:13:19 By : Mr. Tony Wang

Desktop Metal, a supplier of mass production additive manufacturing (AM) solutions, has used 4140 low alloy steel for the production system platform, which uses the patent-pending single-pass jet (SPJ) technology to achieve the fastest Speed ​​up the development of the metal additive manufacturing industry.

Desktop Metal is the first and only company to use 4140 low-alloy steel in a metal binder spray system, enabling it to be used in mass-produced end-use parts applications.

4140 is considered to be one of the most widely used low-alloy steels. It is a key general-purpose and heat-treatable steel, widely used in various automotive, oil and gas, and industrial applications, such as gears, downhole tool parts, couplings, Spindles, bolts and nuts, and many other mechanical parts.

Power steering connector. Source: Desktop Metal.

4140 has always been a challenging material for metal binder injection because of its low alloy content, strict carbon control requirements, and low ignition energy, which require advanced binder chemistry, as well as extensive printing and sintering optimization and Atmospheric control for safe processing.

We are very pleased to be the first company to certify 4140 for metal adhesive spraying, making this versatile material suitable for the AM industry. With the speed of the production system, companies can now use adhesive jets to print complex 4140 parts at a competitive cost, while maintaining the strength and mechanical properties of traditional manufacturing alternatives. For manufacturers who are constrained by time-consuming and expensive machining and traditional tool-based manufacturing processes, this is a game-changing solution. ——Jonah Myerberg, co-founder and CTO of Desktop Metal

Desktop Metal’s materials science team has verified that the 4140 low-alloy steel printed using production system technology and sintered by Desktop Metal meets the MPIF 35 standard for structural powder metallurgy parts established by the Metal Powder Industry Federation.

The 4140 parts printed on the production system platform not only eliminates the use of tools and minimizes material waste, but also significantly reduces production time and parts costs compared with traditional manufacturing methods.

Power steering connector. This joint is used for power transmission between the electric power steering motor and the steering shaft of the car. The 4140 has excellent strength and hardness, which is essential to connect this part to the spline teeth of the rest of its assembly. Although the use of traditional presses and sintering processes for production requires expensive molds, the production system P-50 can achieve mold-free production, shorten delivery time, and achieve more flexible design while fully burdening the cost of parts, with an annual output of up to 1.2 million pieces are as low as US$2.45.

Herringbone gears. Herringbone gears are widely used in various industrial machinery applications, benefiting from the excellent hardness of 4140 low-alloy steel, and can use complex lattice design achieved through additive manufacturing to reduce weight, thereby reducing material costs and reducing external component wear , Such as motors and bearings. This part can be mass-produced on the production system P-50 in quantities of up to 200,000 parts per year, with 120 parts nested each time.

Linear pneumatic piston. Linear pneumatic pistons are used to convert air pressure into rotary motion through racks and pinions. The 4140 provides the toughness and wear resistance required for this application. Due to the geometric shape and cost constraints of traditional manufacturing processes, these parts are traditionally assembled from multiple components. The production system P-50 can produce up to 690,000 parts per year at a cost as low as US$0.28 per cubic centimeter of sintered 4140 low-alloy steel.

Lever drive. Lever drives are usually used in machine design to linearly adjust the position of parts in the machine. Adhesive jets can easily promote features, such as precision grooves that are critical to positioning the correct location of external components. Considering the cost of up-front tooling or labor costs related to machining, producing 10,000 medium-volume parts is not cost-effective in traditional manufacturing. The production system P-50 can print the required number of sintered parts in one day in less than a week Time.

production system. The production system created by the inventor of adhesive jetting and single-pass inkjet technology is an industrial manufacturing platform supported by Desktop Metal's SPJ technology. It aims to achieve up to 100 times the speed of traditional powder bed fusion additive manufacturing technology, and can produce up to millions of parts every year at a competitive cost compared with traditional mass production technology.

The production system platform consists of two printer models: P-1, a solution for process development and mass production applications, and P-50, a large mass production solution for end-use parts, scheduled for 2021 The second half of the year.

The production system combines desktop metal engineering adhesives with an open material platform, enabling customers to produce high-performance parts using the same low-cost metal powders used in the metal injection molding (MIM) industry. The inert processing environment is compatible with a variety of materials, including 4140 low-alloy steel and other high-performance alloys, and even active metals such as aluminum and titanium.

Today, the Production System platform material library includes 17-4 PH stainless steel, 316L stainless steel and 4140 low alloy steel, all of which have passed Desktop Metal certification. The platform also supports a variety of materials that meet customer requirements, including silver and gold. Desktop Metal plans to add other metals to its product portfolio, including tool steel, stainless steel, high-temperature alloys, and copper.

Published on June 8, 2021 in 3D Printing, Manufacturing, Materials | Permalink | Comments (0)

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