Fathom 3D printing technology advances

(Blog opening part)

The manufacturing landscape is undergoing an earthquake shift, driven by the ruthless innovation of additive manufacturing (AM), commonly known as 3D printing. For engineers, designers and procurement experts in various industries, from aerospace to medical equipment, automobiles to energy, staying ahead means understanding how these advancements translate into real-world production capacity. At Greatlight, we leverage cutting-edge Fathom 3D printing technology to deliver unparalleled rapid prototype and end-use parts solutions, especially focused on precise metal components. This in-depth dive explores the most important technological leap in the Fathom ecosystem and how they enable manufacturers to solve complex challenges faster and more efficiently than ever before.

Unlocking Metal Potential: Advanced Powder Bed Fusion

The core strength of Greglight is our Selective laser melting (SLM)a major powder bed fusion (PBF) technology. Recent leaps to integrate seamlessly with our compatible systems:

1. High power, multi-tube rider system: Modern Fathom SLM printers use multiple high-power lasers simultaneously. This is more than just the original speed; it allows for complex laser overlap strategies, scanning mode optimization, and seamless construction of large parts without thermal distortion penalties. Need a large, complex aerospace bay or hydraulic manifold overnight? Multi-laser functionality makes this possible.
2. Advanced real-time monitoring and process control:

   • Melt pool monitoring: High resolution pyrometers, sometimes in-situ cameras monitor laser-material interaction areas in real time. This allows immediate detection of abnormalities such as splashing, lack of fusion or overheating, thereby potential adjustments to perform post-processing checks during the build process or at least marked.
   • Quality assurance at level: Automatic powder layer repeat verification system and optical consistency check ensure that each layer of powder is completely uniform before melting, eliminating early source of defects.
   • Closed-loop feedback Inteligencia: The software aggregates sensor data to dynamically adjust laser power, scanning speed, and spot size in the layer according to local geometry, reducing thermal stress and ensuring that the entire most complex component is consistent.

3. Extended material horizons: FATHOM technology paired with our expertise can make metal alloys that go beyond standard titanium (Ti6al4v) and stainless steel (316L) increasingly complex. This includes:

   • High temperature alloy: Inconel 625, 718, even for refractory metals that require aerospace and energy applications.
   • Reactive metals: Pure titanium, aluminum alloys (ALSI10MG, ScalMalloy) and copper alloys require professional inert gas treatment with advanced systems.
   • Tool Steel: H13, Maraging Steel (MS1) produces durable conformal treatment tool inserts for injection molding.
   • Customized materials are made of: Greglight can work with you to make proprietary powder ingredients for professional applications, leveraging Fathom’s process flexibility.

Beyond one layer: Adhesive spray appears

SLM excels in producing high-strength, complex geometry, and Fathom also contains Binder jet (BJ) Technology with unique advantages:

• Unparalleled production speed and scalability: BJ deposits the adhesive on the powder layer, skipping the time-consuming laser melting of each layer. This allows for large-scale parallel processing – the entire part can be built simultaneously in hours, greatly reducing the cost per part to meet higher volume requirements.
• Geometric freedom without support: The powder bed naturally supports overhang during printing, eliminating design limitations and post-treatment related to removing SLM support structures.
• Material Diversity: BJ is compatible with a wide range of powder materials including a wide variety of stainless steels, tool steels, and even development ceramics.
• Overall sintering enhancement: Advances in the sintering furnace profile and deletion techniques are crucial to achieve final strength and density, ensuring that the mechanical properties of the BJ parts are getting closer to the forged material, making them feasible for a wider range of functional components.

Great Advantage: Engineering Solutions, Not Just Parts

Our expertise goes far beyond operating only advanced FATHOM machines. We provide engineering solutions:

• Design of Additive Manufacturing (DFAM): Work with our engineers from the conceptual stage to ensure that your part leverages the true potential of AM – topological optimization, part merging, weight loss and functional integration (such as conformal cooling channels) become tangible reality.
• Integrated one-stop post-processing: Printed parts are just the starting point. Greglight offers comprehensive finishing services under one roof:

  • Heat treatment: Stress relief, hips (hot etc. are still), to eliminate pores, solution treatment and aging.
  • Precision machining (CNC): Achieving the final dimension and tight tolerances is critical for mating surface or bearing fitting.
  • Surface finish: A wide selection of CNC machining, conventional polishing, EDM, laser finishing and media explosions, as well as advanced processes such as Shot Peening (resistant to fatigue), electropolishing or specialized coatings.
  • Supports removal and surface treatment: Work carefully to ensure the original final part.

• Quick iteration and verification: Crucially, these advanced features converge to significantly shorten the development cycle. Functional metal prototypes for rigorous testing or production tool insertion can be transferred from digital files to the verified section in days rather than weeks or months. Failure is faster and cheaper, resulting in the fastest final design.
• Cost Optimization: Through the merger process, optimized construction, reduced material waste and subtraction methods, and achieve innovative part design, Advanced AM always reduces total part costs, especially for complex, low to medium quantity components.

(Conclusion section)

The evolution of Fathom 3D printing technology, especially in SLM and Binder jets, represents a quantum leap in manufacturing capabilities. These systems are no longer downgraded to simple prototyping. They are exquisite production platforms that enable the creation of end-use parts with complex geometric shapes, special material properties and unprecedented design freedom. Great, as a leading provider of rapid prototyping and precision metal AM solutions leverages these advanced Fathom systems, embodying this conversion.

Our commitment is to leverage this technology not only to print parts, but also to solve it your Create challenges. From initial design consulting firms (DFAM) and material selection, we provide a truly end-to-end solution through high-precision printing with multi-laser SLM or large BJ, seamless integration with industry-leading post-processing and completions. Results: Accelerate innovation, reduce development costs, lighter, more powerful products, and partial designs that were previously unimaginable. The future of manufacturing is additive and is happening in Greatlight now.

(FAQ section)

1. Q: Why choose Greatlight for metal 3D printing?
   one: In addition to state-of-the-art Fathom SLM and BJ equipment, Greatlight offers DFAM’s deep engineering expertise, fast customization of materials and processes, unrivalled speed production of functional prototypes and end-use parts, and a critical one-stop service including precision machining and advanced surface treatments. We focus on solving your specific problems, not just printing parts.

2. Q: What makes FATHOM SLM technology superior?
   one: Modern FATHOM SLM systems utilize multi-laser configurations for speed and scale, incorporate complex real-time monitoring (melt pool, QA layer) into unprecedented process control and reliability, and provide extraordinary compatibility with a wide range of high-performance metal alloys, which is critical to demanding industries. Closed-loop process optimization ensures consistent high-quality results.

3. Q: What are the main advantages of adhesive jet (BJ) compared to SLM?
   one: Adhesive spraying is excellent with extremely high build speeds and volume throughput, which greatly reduces the cost of each portion, especially for medium-sized volumes. It eliminates the support structure, provides obvious geometric freedom, handles different materials and colors, including single and bimetallic powders as well as ceramics, and is inherently scalable. The final strength occurs after sintering and optional wetting.

4. Q: Can Greatlight produce parts using certified materials?
   one: Absolutely. We usually deal with industry standard grades such as TI6AL4V (Grade 5 and 23), 316L stainless steel, ALSI10MG, Inconel 718 and 625 and various tool steels. We comply with strict quality control protocols and can support material certification requirements. We can also explore custom material qualifications.

5. Q: What tolerances can be achieved?
   one: Depending on geometry, size and material, the SLM tolerance of ASPINT is typically ±0.1 mm to ±0.2 mm. Adhesive jet part pre-sockets have similar tolerances but shrink during sintering. Crucially, Greatlight provides internally accurate CNC machining to require micro-level tolerances (±0.025 mm or higher) in part of our finishing service.

6. Q: What type of post-processing do you provide?
   one: Our comprehensive services include demolition structures, a variety of heat treatments (stress relief, hips, solution treatment/aging), precise CNC machining, massive surface finishes (sanding, polishing, polishing, electropolishing, shooting), EDM finishes and custom coatings. We customize post-processing chains to meet your exact functional and aesthetic requirements.

7. Q: How "One-stop" Service saves time and cost?
   one: By managing the entire workflow under one roof – from DFAM consultation and document preparation, to printing (SLM/BJ), all critical post-processing steps (hotspot, machining, machining, finishing) and final inspections – we eliminate management overhead, logistical delays, communication gaps between suppliers, and potential quality differences. This simplifies your supply chain and speeds up time to market.

8. Q: Is your solution suitable for mass production?
   one: Yes. While we specialize in rapid prototyping, low to medium production runs are a strength, especially leveraging the scalability and cost-effectiveness of adhesive jet technology. SLM is still ideal for complex, high-performance parts that require lower volumes (ten dozens). We extend the process to effectively meet your specific quantity needs.

Ready to experience the future of metal manufacturing?

Don’t let complicated designs or lead times stop you from retreating. Unlock innovation and accelerate your product development with Greatlight’s cutting-edge Fathom 3D printing expertise and a complete one-stop service.
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