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Meltio Horizon
Does the Meltio Horizon software offer any differences compared to others? Is it worth switching from another software to Meltio Horizon when using this technology?
Unlike Simplify3D, which is a software designed for plastic printing (known as FDM), Meltio Horizon software is exclusively designed for Meltio’s laser wire metal printing technology. It is a software that offers advantages over the previous one since it facilitates the creation of complex parts.
With Simplify3D, the printing parameters are applied to the entire part, while with our Software we can control the parameters independently in each section, that is, we can apply different power, speed, material flow rate etc. to the outer perimeter, inner perimeter, or infill perimeter as well as modifier regions offering the user more control for a faster and more precise printing process.
Can I create my own profile in Meltio Horizon?
Yes, we allow users to create profiles from zero. You can start by using the default profiles provided by Meltio and then the user can modify it accordingly depending on the materials by running a series of tests to optimize the part to the maximum.
Using a base profile will allow the user to receive a series of visual and interface outputs. This feedback is quite useful because it will help the user to automatize the process and once the part is fully optimized, it will be as simple as Plug & Play.
Which extension works with the Meltio Horizon slicer?
The file type that Meltio Horizon works with is STL. This format approximates the surface of a solid model with triangles and can be generated with almost any CAD software.
What is a Workspace? How do we create a Workspace?
The Workspace is a file, similar to other types of slicer files such as “factory files”, which combines a model in STL format, together with the saved printing parameters, to later have the possibility of generating the gcode to be able to print it.
It is highly recommended to generate the Workspace together with the gcode to have the possibility of changing the printing parameters to perform iterations of the same model, or when inspecting how the gcode of a part with a specific geometry was generated in other applications. Gcode is used to print with our Standalone systems.
The process to follow to create a Workspace is as follows:
Once we have our Stl. extension, we export it to the slicer, establish some parameters adapted to our geometry and, from there, we generate a gcode. If we are interested in modifying the parameters of that gcode because after having tried to print, we need to modify any parameter, we need to create our Workspace file. Once we are in our Workspace, from now on we can access the project and modify parameters or create new gcodes from scratch using the parameters already defined for our previous part as a base.
Does the Meltio Horizon software offer any differences compared to others? Is it worth switching from another software to Meltio Horizon when using this technology?
Unlike Simplify3D, which is a software designed for plastic printing (known as FDM), Meltio Horizon software is exclusively designed for Meltio’s laser wire metal printing technology. It is a software that offers advantages over the previous one, since it facilitates the creation of complex parts. Why is this? What changes are there for this to happen?
With Simplify3D, the printing parameters are applied to the entire part, while with our Software we can control the parameters independently in each section, that is, we can apply different power, speed, material flow rate etc. to the outer perimeter, inner perimeter, or infill perimeter as well as modifier regions offering the user more control for a faster and more precise printing process.
Can I create my own profile in Meltio Horizon?
Yes, we allow users to create profiles from zero. You can start by using the default profiles provided by Meltio and then the user can modify it accordingly depending on the materials by running a series of tests to optimize the part to the maximum.
Using a base profile will allow the user to receive a series of visual and interface outputs. This feedback is quite useful because it will help the user to automatize the process and once the part is fully optimized, it will be as simple as Plug & Play.
Which extension works with the Meltio Horizon slicer?
The file type that Meltio Horizon works with is STL. This format approximates the surface of a solid model with triangles and can be generated with almost any CAD software.
What is a Workspace? How do we create a Workspace?
The Workspace is a file, similar to other types of slicer files such as “factory files”, which combines a model in STL format, together with the saved printing parameters, to later have the possibility of generating the gcode to be able to print it.
It is highly recommended to generate the Workspace together with the gcode to have the possibility of changing the printing parameters to perform iterations of the same model, or when inspecting how the gcode of a part with a specific geometry was generated in other applications. Gcode is used to print with our Standalone systems.
The process to follow to create a Workspace is as follows:
Once we have our Stl. extension, we export it to the slicer, establish some parameters adapted to our geometry and, from there, we generate a gcode. If we are interested in modifying the parameters of that gcode because after having tried to print, we need to modify any parameter, we need to create our Workspace file. Once we are in our Workspace, from now on we can access the project and modify parameters or create new gcodes from scratch using the parameters already defined for our previous part as a base.
Meltio M600
- Materials
- Deposition Rate
- Productivity
- Maintenance
- Turn Around
- Load Time
- Wire Change
- Large Wire Drum
- Heaviest Part
- Repeatability
- Blue Lasers
- Blue Lasers Lifetime
- Laser Fibers
- Resume Printing
Which materials can be printed by the Meltio M600?
The Meltio M600 can process the complete range of current Meltio materials along with additional copper and aluminum alloys.
For copper alloys, Meltio has begun working with the following materials:
ERCuNiAl: Bronze for marine applications that is fully printable and speeds comparable to stainless steel.
CuCrZr: Copper Chromium Zirconium alloy used for its excellent conductivity and mechanical properties. This material is currently printable for structures that have thin walls and high aspect ratios such as Heat Exchangers, however further work needs to be done for parameterization.
In regards to Aluminium alloys, we have been working with both 5000 Series and 6000 Series alloys which are printable and have produced fully dense results, however the surface finish and ability to reproduce small features is not fully developed yet, meaning that parts can be produced but their appearance is below the standard that we see for most Meltio parts.
What is the deposition rate of your machines?
The Meltio M600 is approximately 60% more productive than current Meltio technology.
However, we do not like the metric of Deposition rate as it varies drastically depending on the geometry, properties, and material of the parts that are printed.
We feel that Deposition rate is a concept that is understood differently by different actors in the industry (Just deposition, Bad properties at high deposition rates, simple geometries, no cooldown time).
We therefore prefer the metric of Productivity / Duty Cycle.
Based on our mix of parts and materials we have produced over the past year we have achieved a productivity of approximately 3200kg / Year with relatively loose production planning and without tending the machine on weekends.
How do we achieve such a high productivity?
The M600 is a production machine that can work fully unattended for large periods of time which is a significant improvement over systems that are commonly found in the market.
We have produced parts with print times over 2 weeks fully unattended.
Maintenance / Running cost
As the M600 is designed for frequent use we have put a big focus on improving the lifetime of the consumables as well as reducing their cost. The wire nozzles for the M600 last approximately twice as long and cost half as much for example. This story is repeated on all consumables.
And lastly, for extra peace of mind, we offer deposition head refurbishments with a cost structure that is based on how many hours the machine has been used, meaning that if something fails before its nominal lifetime it will not break your cost model, and laser degradation is capped at less than 1 Euro per hour in case of failure.
How much time does it take to turn the printer around for another part?
Build plate exchanges and basic cleaning and maintenance takes about 15 minutes.
For production workflows using the zero point clamping system the machine can be turned around in less than 1 minute considering a 15 minutes of daily downtime for maintenance. In addition to saving the set up time for post processing (CNC, EDM).
How long does it take to load material into the printer?
Loading a new spool of material or connecting an external wire drum takes approximately 5 minutes of operator time.
How long does it take to exchange the material within the print?
Automated wire changes make use of the Built in Wire Cutter for maximum reliability and take approximately 20 seconds to complete.
How do I connect a large wire drum to the machine?
Connecting Wire Drums to the printer is easy thanks to the “External Wire Drum Kit” that includes all the parts to connect bulk material sources to the M600. The kit contains a roller wire guide for extra smooth and reliable feeding.
What is the heaviest part you can print?
The Meltio M600 can print parts in excess of 100 kg of deposited weight. The recommended maximum weight of the part + build plate is 150kg.
Why is this printer more repeatable than others?
The Meltio M600 is more reliable and repeatable than machines in its class because it fuses the process knowledge that we have gained from installing over 300 Laser Wire DED Machines with a really stable motion platform powered by servo motors and linear encoders.
The M600 leaves the factory fully calibrated, it removes operator touchpoints such as laser calibration for more stability and features a variety of sensors for process monitoring and an improved process control system.
What are the benefits of Blue lasers?
Blue lasers (450 nm) are beneficial for the processing of most materials as the shorter wavelength is absorbed more by most metals and particularly by Aluminium and Copper where blue light is absorbed over 10X more compared to most industrial lasers operating in the Near infrared wavelength range of 950-1100 nm.
This increase in absorption is directly contributing to the energy efficiency of the system as less energy is lost due to reflection. This is how the Meltio M600 prints significantly faster than the previous Meltio products while the actual laser power is reduced. It also means that the production process is more environmentally friendly and your energy bill is lower as well.
What is the lifetime of the Blue lasers?
The Median lifetime of the Blue laser deposition head is 20.000h when operated at full power at all times. Thanks to the refurbishment options for the deposition head the cost of laser degradation is effectively managed as users can replace their head with a refurbished unit at a low cost. Note: Lifetime is defined as the period of time at the end of which the lasers only produce 80% of their nominal output.
Does the M600 use laser fibers?
No, the Meltio M600 is the first Meltio product that integrates the lasers directly into its deposition head. Not only does this make the system more robust, it also increases the efficiency of the laser system as fiber coupling losses (i.e. energy that is generated but does not enter the laser fiber) are removed. It also means that the laser head is its own self-contained subassembly for easy servicing.
Can I resume a print after it failed, ran out of material or the lights went out?
Yes, the Meltio M600 makes it easy to resume a print if anything goes wrong. Thanks to the absolute encoders the last position is saved and the printer on resume the printer returns to these coordinates to continue printing. Even if you open the door and move the print bed around.
Which materials can be printed by the Meltio M600?
The Meltio M600 can process the complete range of current Meltio materials along with additional copper and aluminum alloys.
For copper alloys, Meltio has begun working with the following materials:
ERCuNiAl: Bronze for marine applications that is fully printable and speeds comparable to stainless steel.
CuCrZr: Copper Chromium Zirconium alloy used for its excellent conductivity and mechanical properties. This material is currently printable for structures that have thin walls and high aspect ratios such as Heat Exchangers, however further work needs to be done for parameterization.
In regards to Aluminium alloys, we have been working with both 5000 Series and 6000 Series alloys which are printable and have produced fully dense results, however the surface finish and ability to reproduce small features is not fully developed yet, meaning that parts can be produced but their appearance is below the standard that we see for most Meltio parts.
What is the deposition rate of your machines?
The Meltio M600 is approximately 60% more productive than current Meltio technology.
However, we do not like the metric of Deposition rate as it varies drastically depending on the geometry, properties, and material of the parts that are printed.
We feel that Deposition rate is a concept that is understood differently by different actors in the industry (Just deposition, Bad properties at high deposition rates, simple geometries, no cooldown time).
We therefore prefer the metric of Productivity / Duty Cycle.
Based on our mix of parts and materials we have produced over the past year we have achieved a productivity of approximately 3200kg / Year with relatively loose production planning and without tending the machine on weekends.
How do we achieve such a high productivity?
The M600 is a production machine that can work fully unattended for large periods of time which is a significant improvement over systems that are commonly found in the market.
We have produced parts with print times over 2 weeks fully unattended.
Maintenance / Running cost
As the M600 is designed for frequent use we have put a big focus on improving the lifetime of the consumables as well as reducing their cost. The wire nozzles for the M600 last approximately twice as long and cost half as much for example. This story is repeated on all consumables.
And lastly, for extra peace of mind, we offer deposition head refurbishments with a cost structure that is based on how many hours the machine has been used, meaning that if something fails before its nominal lifetime it will not break your cost model, and laser degradation is capped at less than 1 Euro per hour in case of failure.
How much time does it take to turn the printer around for another part?
Build plate exchanges and basic cleaning and maintenance takes about 15 minutes.
For production workflows using the zero point clamping system the machine can be turned around in less than 1 minute considering a 15 minutes of daily downtime for maintenance. In addition to saving the set up time for post processing (CNC, EDM).
How long does it take to load material into the printer?
Loading a new spool of material or connecting an external wire drum takes approximately 5 minutes of operator time.
How long does it take to exchange the material within the print?
Automated wire changes make use of the Built in Wire Cutter for maximum reliability and take approximately 20 seconds to complete.
How do I connect a large wire drum to the machine?
Connecting Wire Drums to the printer is easy thanks to the “External Wire Drum Kit” that includes all the parts to connect bulk material sources to the M600. The kit contains a roller wire guide for extra smooth and reliable feeding.
What is the heaviest part you can print?
The Meltio M600 can print parts in excess of 100 kg of deposited weight. The recommended maximum weight of the part + build plate is 150kg.
Why is this printer more repeatable than others?
The Meltio M600 is more reliable and repeatable than machines in its class because it fuses the process knowledge that we have gained from installing over 300 Laser Wire DED Machines with a really stable motion platform powered by servo motors and linear encoders.
The M600 leaves the factory fully calibrated, it removes operator touchpoints such as laser calibration for more stability and features a variety of sensors for process monitoring and an improved process control system.
What are the benefits of Blue lasers?
Blue lasers (450 nm) are beneficial for the processing of most materials as the shorter wavelength is absorbed more by most metals and particularly by Aluminium and Copper where blue light is absorbed over 10X more compared to most industrial lasers operating in the Near infrared wavelength range of 950-1100 nm.
This increase in absorption is directly contributing to the energy efficiency of the system as less energy is lost due to reflection. This is how the Meltio M600 prints significantly faster than the previous Meltio products while the actual laser power is reduced. It also means that the production process is more environmentally friendly and your energy bill is lower as well.
What is the lifetime of the Blue lasers?
The Median lifetime of the Blue laser deposition head is 20.000h when operated at full power at all times. Thanks to the refurbishment options for the deposition head the cost of laser degradation is effectively managed as users can replace their head with a refurbished unit at a low cost. Note: Lifetime is defined as the period of time at the end of which the lasers only produce 80% of their nominal output.
Does the M600 use laser fibers?
No, the Meltio M600 is the first Meltio product that integrates the lasers directly into its deposition head. Not only does this make the system more robust, it also increases the efficiency of the laser system as fiber coupling losses (i.e. energy that is generated but does not enter the laser fiber) are removed. It also means that the laser head is its own self-contained subassembly for easy servicing.
Can I resume a print after it failed, ran out of material or the lights went out?
Yes, the Meltio M600 makes it easy to resume a print if anything goes wrong. Thanks to the absolute encoders the last position is saved and the printer on resume the printer returns to these coordinates to continue printing. Even if you open the door and move the print bed around.
Density
How can I achieve maximum density in my printing model?
At Meltio, we have two types of printing profiles: “Density Verified Profiles” and “Utility Printing Profiles”.
First of all, it is important to know that both profiles have been obtained from the results of phase I of materials characterization. In this phase, tests are carried out based on energy density, and 3 Process Bands are identified: Lack of Fusion, Minor Defects, and Fully Dense Parts. In the “Density Verified Profiles” high-density results are achieved, obtaining fully dense parts, while in the “Utility Printing Profiles,” the results show minor defects whose effect on the final quality of the piece should be minimal.
Therefore, once we know this, if we want maximum density, the “Density Verified Profiles” allow us to obtain maximum density. Parts printed in this region do not show any defects that can be detected using CT Scanning. Density measurements beyond this point must be performed using metallography. We find that parts in this region typically show densifications greater than 99.99%. This however comes at the price of print speed which is typically much lower.
What if I don’t want to get a part with maximum density?
If you do not care so much about not obtaining a part with maximum density, you can then opt for the “Utility Printing Profiles” profile, since the results show minor defects and whose effect on the final quality of the part should be minimal.
Parts printed in this range generally do not show defects that are visible to the naked eye and perform well mechanically. Defect size is generally smaller than 250 microns but may affect the fatigue life of the component adversely.
For what cases should I use the “Density Verified Profiles” profile?
You may be interested in using this profile to close a process when you are going to do a material characterization for internal tests or when you want to make high-quality parts in the material when your application standard requires high densification.
What do I have to do to get a hollow piece?
For optimal printing of a hollow component with Meltio Horizon, it is advised to begin with a solid CAD model. Export the model to STL, and within Meltio Horizon, choose the preferred contour thickness while setting the “Thin wall infill” as None and the “Infill Density” to 0%.
This approach enables the software to interpret the contour as a singular entity, resulting in a geometry with enhanced thickness accuracy.
Alternatively, utilizing a hollow CAD model is feasible, although it should be noted that Meltio Horizon may recognize the single wall as a dual-entity contour. Consequently, the printing path will be duplicated during the printing process, leading to an increased thickness in the contour.
How can I achieve maximum density in my printing model?
At Meltio, we have two types of printing profiles: “Density Verified Profiles” and “Utility Printing Profiles”.
First of all, it is important to know that both profiles have been obtained from the results of phase I of materials characterization. In this phase, tests are carried out based on energy density, and 3 Process Bands are identified: Lack of Fusion, Minor Defects, and Fully Dense Parts. In the “Density Verified Profiles” high-density results are achieved, obtaining fully dense parts, while in the “Utility Printing Profiles,” the results show minor defects whose effect on the final quality of the piece should be minimal.
Therefore, once we know this, if we want maximum density, the “Density Verified Profiles” allow us to obtain maximum density. Parts printed in this region do not show any defects that can be detected using CT Scanning. Density measurements beyond this point must be performed using metallography. We find that parts in this region typically show densifications greater than 99.99%. This however comes at the price of print speed which is typically much lower.
What if I don’t want to get a part with maximum density?
If you do not care so much about not obtaining a part with maximum density, you can then opt for the “Utility Printing Profiles” profile, since the results show minor defects and whose effect on the final quality of the part should be minimal.
Parts printed in this range generally do not show defects that are visible to the naked eye and perform well mechanically. Defect size is generally smaller than 250 microns but may affect the fatigue life of the component adversely.
For what cases should I use the “Density Verified Profiles” profile?
You may be interested in using this profile to close a process when you are going to do a material characterization for internal tests or when you want to make high-quality parts in the material when your application standard requires high densification.
What do I have to do to get a hollow piece?
For optimal printing of a hollow component with Meltio Horizon, it is advised to begin with a solid CAD model. Export the model to STL, and within Meltio Horizon, choose the preferred contour thickness while setting the “Thin wall infill” as None and the “Infill Density” to 0%.
This approach enables the software to interpret the contour as a singular entity, resulting in a geometry with enhanced thickness accuracy.
Alternatively, utilizing a hollow CAD model is feasible, although it should be noted that Meltio Horizon may recognize the single wall as a dual-entity contour. Consequently, the printing path will be duplicated during the printing process, leading to an increased thickness in the contour.
How can I achieve maximum density in my printing model?
At Meltio, we have two types of printing profiles: “Density Verified Profiles” and “Utility Printing Profiles”.
First of all, it is important to know that both profiles have been obtained from the results of phase I of materials characterization. In this phase, tests are carried out based on energy density and 3 Process Bands are identified: Lack of Fusion, Minor Defects and Fully Dense Parts. In the “Density Verified Profiles” high-density results are achieved, obtaining fully dense parts, while in the “Utility Printing Profiles” the results show minor defects whose effect on the final quality of the piece should be minimal.
Therefore, once we know this, if we want maximum density, the “Density Verified Profiles” allow us to obtain maximum density. Parts printed in this region do not show any defects that can be detected using CT Scanning. Density measurements beyond this point must be performed using metallography. We find that parts in this region typically show densifications greater than 99.99%. This however comes at the price of print speed which is typically much lower.
What if I don't want to get a part with maximum density?
If you do not care so much about not obtaining a part with maximum density, you can then opt for the “Utility Printing Profiles” profile, since the results show minor defects and whose effect on the final quality of the part should be minimal.
Parts printed in this range generally do not show defects that are visible to the naked eye and perform well mechanically. Defect size is generally smaller than 250 microns but may affect fatigue life of the component adversely.
For what cases should I use the “Density Verified Profiles” profile?
You may be interested in using this profile to close a process when you are going to do a material characterization for internal tests or when you want to make high-quality parts in the material when your application standard requires high densification.
What do I have to do to get a hollow piece?
For optimal printing of a hollow component with Meltio Horizon, it is advised to begin with a solid CAD model. Export the model to STL, and within Meltio Horizon, choose the preferred contour thickness while setting the “Thin wall infill” as None and the “Infill Density” to 0%.
This approach enables the software to interpret the contour as a singular entity, resulting in a geometry with enhanced thickness accuracy.
Alternatively, utilizing a hollow CAD model is feasible, although it should be noted that Meltio Horizon may recognize the single wall as a dual-entity contour. Consequently, the printing path will be duplicated during the printing process, leading to an increased thickness in the contour.
Materials
Is there any information about Tungsten Carbide cladding?
It is not a material we have released yet but we have tested it. Contact us if you want more information about these results.
What information do you have about residual stress?
Depends on each material, application, geometries, and requirements… Noncritical applications in stainless steel can generally be used in as-printed conditions. A relatively massive part of tool steel would require an annealing heat treatment before removal from the build plate to avoid cracking.
Have you found any porosity within the weld layers?
We have a process qualifiication for each material so we test a lot of different parameters and we approve the ones that are showing no porosity. This is done by a first set of process qualification with samples sent to tomography and once we find the ones that they have noporosity, those parameters are the ones that are brought forward for qualification and mechanical properties.
What data do you have for the weld strength?
In terms of the weld strength, that is what you can see as the mechanical properties, we will release some documents in terms of joining the similar materials, but we are not generally seeing our system as a welding process so, for example, we are not testing the material for joining two plates with a butt weld.
Does Meltio utilize powder feedstocks at all?
No, it’s no longer available in Meltio’s product range.
Are there any issues with the wire getting stuck to the workpiece?
Wire doesn’t get stuck to the workpiece, the process control prevents this from happening.
What level of energy input is typically seen with this system?
In terms of energy input, it depends on the material. Our current parameters go for full power, that means 1.1, 1.2 kW. In case it’s a thin wall component, we don’t apply full power as it wouldn’t be able to stand it.
What are your plans for functionally graded materials from a wire feed perspective?
It’s not something we have specific plans but our partners from tech centers and universities are evaluating it. Potentially, with the dual wire you can change the behaviour of the part by changing the number of layers of one material or the other.
Do you have options for 1.2mm wires?
The system works from 0.8mm to 1.2mm wires. All Meltio materials are sold in 1.0mm wire.
Is there any information about Tungsten Carbide cladding?
It is not a material we have released yet but we have tested it. Contact us if you want more information about these results.
What information do you have about residual stress?
Depends on each material, application, geometries, and requirements… Noncritical applications in stainless steel can generally be used in as-printed conditions. A relatively massive part of tool steel would require an annealing heat treatment before removal from the build plate to avoid cracking.
Have you found any porosity within the weld layers?
We have a process qualifiication for each material so we test a lot of different parameters and we approve the ones that are showing no porosity. This is done by a first set of process qualification with samples sent to tomography and once we find the ones that they have noporosity, those parameters are the ones that are brought forward for qualification and mechanical properties.
What data do you have for the weld strength?
In terms of the weld strength, that is what you can see as the mechanical properties, we will release some documents in terms of joining the similar materials, but we are not generally seeing our system as a welding process so, for example, we are not testing the material for joining two plates with a butt weld.
Does Meltio utilize powder feedstocks at all?
No, it’s no longer available in Meltio’s product range.
Are there any issues with the wire getting stuck to the workpiece?
Wire doesn’t get stuck to the workpiece, the process control prevents this from happening.
What level of energy input is typically seen with this system?
In terms of energy input, it depends on the material. Our current parameters go for full power, that means 1.1, 1.2 kW. In case it’s a thin wall component, we don’t apply full power as it wouldn’t be able to stand it.
What are your plans for functionally graded materials from a wire feed perspective?
It’s not something we have specific plans but our partners from tech centers and universities are evaluating it. Potentially, with the dual wire you can change the behaviour of the part by changing the number of layers of one material or the other.
Do you have options for 1.2mm wires?
The system works from 0.8mm to 1.2mm wires. All Meltio materials are sold in 1.0mm wire.
Is there any information about Tungsten Carbide cladding?
It is not a material we have released yet but we have tested it. Contact us if you want more information about these results.
What about residual stress?
What information do you have about residual stress?
Depends on each material, application, geometries, and requirements… Noncritical applications in stainless steel can generally be used in as-printed conditions. A relatively massive part of tool steel would require an annealing heat treatment before removal from the build plate to avoid cracking.
Did you try pure tungsten?
It’s in our plans. Stay tuned.
Have you found any porosity within the weld layers?
We have a process qualifiication for each material so we test a lot of different parameters and we approve the ones that are showing no porosity. This is done by a first set of process qualification with samples sent to tomography and once we find the ones that they have noporosity, those parameters are the ones that are brought forward for qualification and mechanical properties.
What data do you have for the weld strength?
In term of the weld strength, that is what you can see as the mechanical properties, we will release some documents in terms of joining the similar materials, but we are not generally seeing our system as a welding process so, for example, we are not testing the material for joining two plates with a butt weld.
Does meltio utilize powder feedstocks at all? Also, with wire, are there any issues with wire getting stuck to the workpiece? Does meltio have point cloud capabilities intergrated into this system? What level of energy input is typically seen with this system?
No, it’s no longer available in Meltio’s product range. Wire doesn’t get stuck to the workpiece, the process control prevents this from happening. In terms of energy input, depends on the material. Our current parameters go for full power, that means 1.1, 1.2 kW. In case it’s a thin wall component, we don’t apply full power as it wouldn’t be able to stand it.
What are your plans for functionally graded materials from a wire feed perspective?
It’s not something we have specific plans but our partners from tech centers and universities are evaluating it. Potentially, with the dual wire you can change the behaviour of the part by changing the number of layers of one material or the other.
Do you have options for 1.2mm wires?
The system works from 0.8mm to 1.2mm wires. All Meltio materials are sold in 1.0mm wire
Technology
Can you compare LMD with WAAM methods?
One main aspect is that the energy source in LMD is completely independent of the material feed so there’s much more flexibility in terms of controlling the process compared to when you’re working with the WAAM.
In those based processes the arc is generated between the feedstock and the substrate so it’s harder to keep the process controlled and also, generally, WAAM develops more heat, therefore a larger HAZ and more spatter. To sum up, a properly controlled LMD process allows for higher resolution compared to WAAM, but it’s not as fast.
Can you compare LMD with powder?
The feed stock is constantly in contact with the substrate so it allows a better control of the process and we’re not wasting any material within our build.
Is your technique limited to vertical printing or can you print sideways aswell?
We can print in any side.
How deep is the heat penetration?
About a full previous layer.
Can you compare LMD with WAAM methods?
One main aspect is that the energy source in LMD is completely independent on the material feed so there’s much more flexibility in terms of controlling the process compared when you’re working with the WAAM. In those based processes the arc is generated between the feedstock and the substrate so it’s harder to keep the process controlled and also, generally, WAAM develops more heat, therefore a larger HAZ and more spatter. To sum up, a properly controlled LMD process allows for higher resolution compared to WAAM, but it’s not as fast.
And LMD powder with wire methods
The feed stock is constantly in contact with the substrate so it allows a better control of the process and we’re not wasting any material within our build.
Is your technique limited to vertical printing or can you print sideways aswell?
We can print in any side.
How deep is the heat penetration?
About a full previous layer
Software
Which CAD/CAM software are you using and/or recommending for your system?
In the Meltio M450 and Meltio M600, we use Meltio Horizon and Meltio Space for the Robotic Integration. We also have an open platform. On the Hybrid side, we partnered with several Software Partners that offer compatible solutions: Meltio Software Partners
Which dashboard have you implemented in your system for Quality Assurance?
In terms of QA, we don’t have a solution integrated into the system but we have a continuous process monitoring which can be fed into a quality assurance system. Then, whenever we talk about the robotic implementation there is the possibility of adding external tools in order to monitor the process such as thermography.
Our process control monitors the electrical continuity between the feedstock and the substrate and this allows for a loop that ensures all the materials go where it’s meant to be and we are also monitoring the quality of the melt pool by having a load cell within the deposition head that ensures the process always operates within a predefined range. You can learn more about Meltio Process Control here: https://meltio3d.com/how-does-process-control-work/
What software are you using for your robot simulation?
The software used for the Robot Integration is the Meltio Space.
If the part is worn and you plan to clad it, the location of the surface would be different from the original CAD. Do you modify the CAD accordingly?
It depends on how much worn-out it is because we have a process control so if there are just 1,0mm or 0.4, 0.5mm we can print with the original file and the process control will fill any potential gap.
If we are moving towards a more damaged area, it will be needed to know which is the current substrate that we are working on, so possibly a 3D scan of the surface or a machined area reflected in the CAD, to start printing.
Does your software add in some sort of compensation for heat deformation?
No, not yet. Also, because our tool head has a control over the amount of power we are depositing to the wire, normally we don’t have that much deformation because of heating.
Which CAD/CAM software are you using and/or recommending for your system?
In the Meltio M450 and Meltio M600, we use Meltio Horizon and Meltio Space for the Robotic Integration. We also have an open platform. On the Hybrid side, we partnered with several Software Partners that offer compatible solutions: Meltio Software Partners
Which dashboard have you implemented in your system for Quality Assurance?
In terms of QA, we don’t have a solution integrated into the system but we have a continuous process monitoring which can be fed into a quality assurance system. Then, whenever we talk about the robotic implementation there is the possibility of adding external tools in order to monitor the process such as thermography.
Our process control monitors the electrical continuity between the feedstock and the substrate and this allows for a loop that ensures all the materials go where it’s meant to be and we are also monitoring the quality of the melt pool by having a load cell within the deposition head that ensures the process always operates within a predefined range. You can learn more about Meltio Process Control here: https://meltio3d.com/how-does-process-control-work/
What software are you using for your robot simulation?
The software used for the Robot Integration is the Meltio Space.
If the part is worn and you plan to clad it, the location of the surface would be different from the original CAD. Do you modify the CAD accordingly?
It depends on how much worn-out it is because we have a process control so if there are just 1,0mm or 0.4, 0.5mm we can print with the original file and the process control will fill any potential gap.
If we are moving towards a more damaged area, it will be needed to know which is the current substrate that we are working on, so possibly a 3D scan of the surface or a machined area reflected in the CAD, to start printing.
Does your software add in some sort of compensation for heat deformation?
No, not yet. Also, because our tool head has a control over the amount of power we are depositing to the wire, normally we don’t have that much deformation because of heating.
Which CAD/CAM softwares are you using and/or recommending for your system?
In the M450 Meltio Horizon and Meltio Space for Robotic. We also have open platform. In the Hybrid side we partnered with several Software Partners that offer compatible solutions: https://meltio3d.com/software/meltio-software-partners/
Which data acquistion system (dashboard) have you implemented in your system for Quality Assurance?
In terms of QA, we don’t have a solution integrated in the system but we have a continuos process monitoring which can be fed into a quality assurance system. Then, whenever we talk about the robotic implementation there are the possibility of adding external tools in order to monitor the process such as thermography. Our process control monitors the electrical continuity between the feedstock and the substrate and this allows for a loop that ensures all the materials goes where it’s meant to be and we are also monitoring the quality of the melt pool by having a load cell within the deposition head that ensures the process always operates within a predefined range. You can learn more about Meltio Process Control here: https://meltio3d.com/how-does-process-control-work/
What software are you using for your robot simualtion?
Meltio Space
If the part is worn and you plan to clad, the location of the surface would be different from the original CAD. Do you modify the CAD accordingly?
It depends on how much worn-out is because we have a process control so if there are just 1,0mm or 0.4, 0.5mm we can print with the original file and the process control will fill any potential gap. If we are moving towards a more damaged area, it will be needed to know which is the current substrate that we are working on, so possibly a 3D scan of the surface or a machined area reflected in the CAD, to start printing.
Does your software add in some sort of compensation for heat deformation?
No, not yet. Also because our tool head has a control over the amount of power we are depositing to the wire, normally we don’t have that much deformation because of heating.
Applications
Are there examples of applications in architecture or construction?
Replacement of thin sheet metal components require quite extensive formings. They are tool-heavy processes or Manual labor-heavy processes. The possibilty of offering a tool-free solution is quite interesting. We’ve seen some interest in the manufacturing of Metal sculptures made out of thin metal sheets.
Have you ever built a plate 200 to 400 mm height, 9mm thick with SUS316L?
We don’t have that specific case but we have similar ones so it’s something you shouldn’t find any problem with.
What’s the level of dilution you have achieved in cladding applications, particularly in cladding rolls for the steel industry?
The dilution we’ve seen, at least in the materials we tested, is about neligible after 600 micron or so in the substrate so there’s quite limited dilution because of the limited HAZ. Of course, by working on the parameters, this can be increased or diminished, but it also depends on the materials.
Are there examples of application in architecture or construction?
Replacement of thin sheet metals components, those require quite extensive formings. They are tool-heavy processes or Manual labor-heavy processes. The possibilty of offering a tool-free solution is quite interesting. We’ve seen some interest in the manufacturing of Metal sculptures made out of thin metal sheets.
Hi. Have you guys ever build a plate 200 to 400 mm hight, 9mm thick with SUS316L?
We don’t have that specific case but we have similar ones so it’s something you shouldn’t find any problem with
What's the level of dilution you have achieved in cladding applications, particularly in cladding rolls for the steel industry?
The dilution we’ve seen, at least in the materials we tested, is about neligible after 600 micron or so in the substrate so there’s quite limited dilution because of the limited HAZ. Of course, by working on the parameters, this can be increased or diminished, but it also depends on the materials.
Hardware
How heavy is the head? Can you use it with a cobot?
The head’s weight is about 20kg. We suggest the minimum payload must be between 45 to 50kgs in order to guarantee the right rigidity of the system. So if you’re going to use it with a cobot that is capable of handling the load but it’s not giving the right rigidity, your results could be pretty poor. So we suggest investing in a larger industrial robot.
How heavy is the head? And can you use it with a cobot?
The head’s weight is about 20kg. We suggest the minimum payload must be between 45 to 50kgs in order to guaranteee the right rigidity of the system. So if you’re gonna use it with a cobot that is capable of handling the load but it’s not giving the right rigidity, your results could be pretty poor. So we suggest investing in a larger industrial robot.
Calibration
Is there a way to not have to calibrate manually?
Yes, an easier way to do this would be to use our calibration camera. In addition to being much simpler and faster, it allows you to know the status of the calibration through a precise analysis. Likewise, it allows you to track the calibration for each print, so you can refer to previous prints to see the calibration you made.
On the other hand, repeatability is achieved in the calibration process since it is possible to always calibrate with the same parameters in order to always achieve the same result constantly and in this way, avoid the human error that manually calibrating can cause.
In Meltio equipment, it is recommended to calibrate when changing the nozzle to prevent other factors, such as the change in thread position, from affecting the printing process.
In the Meltio M600, this does not need to happen as it comes precalibrated.
Is there a way to not have to calibrate manually?
Yes, an easier way to do this would be to use our calibration camera. In addition to being much simpler and faster, it allows you to know the status of the calibration through a precise analysis. Likewise, it allows you to track the calibration for each print, so you can refer to previous prints to see the calibration you made.
On the other hand, repeatability is achieved in the calibration process since it is possible to always calibrate with the same parameters in order to always achieve the same result constantly and in this way, avoid the human error that manually calibrating can cause.
In Meltio equipment, it is recommended to calibrate when changing the nozzle preventively to prevent other factors, such as the change in thread position, from affecting the printing process.
In the Meltio M600, this does not need to happen as it comes precalibrated.
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