In 2024, green laser 3D printing will mark the collective entry of equipment manufacturers.
Pure copper and copper alloys are widely used in aerospace, machinery manufacturing, automobile, 3C electronics and other fields due to their excellent electrical conductivity, thermal conductivity, corrosion resistance and tenacity. However, the high thermal conductivity, high reflectivity and oxidation sensitivity of pure copper lead to rapid heat diffusion, low laser absorption efficiency and tendency to splash, which poses technical challenges. to 3D printing.
SO,Green laser 3D printerBecome an effective solution to this problem. The short wavelength of the green laser has a higher metal absorption rate than near-infrared lasers, making it a better choice for printing highly reflective metals. Under normal temperature conditions, the absorption rate of copper materials for 1064nm near-infrared laser is less than 5%, while the absorption rate for 532nm green laser can reach 40%, which is 8 times that of traditional near-infrared laser, effectively improving printing efficiency and quality.
Today, LPBF devices based on green lasers have been successfully commercialized. In 2018, TRUMPF took the lead by launching the world’s first green laser 3D printer, the TruPrint 1000 Green Light Edition. The equipment is equipped with a 515nm green laser and can effectively process highly reflective materials such as pure copper, copper alloys and highly reflective materials. precious metals. Subsequently, in 2022, Trumpf launched a new generation of large green light 3D printer TruPrint 5000 green light version.
By 2023, China has achieved a significant breakthrough in the commercialization process of green laser 3D printing equipment. Xihe Additive took the lead in launching XH-M160G equipment, becoming the first domestic manufacturer and the second in the world to successfully market green laser LPBF equipment. In 2024, Xihe Additive will launch XH-M350G equipment again with medium and large casting sizes. As Xihe Additive makes rapid progress in the field of SLM green laser 3D printing, other manufacturers have quickly followed suit.
In May 2024, Hanbang Laser officially launched HBD S400G green laser metal additive manufacturing equipment at TCT Asia, with casting size up to 400 × 350 × 400mm. In July 2024, Bright also announced the launch of a new green laser technology solution, but the specific model has not yet been disclosed. Immediately afterwards, Leiming Laser announced in December the launch of a green laser additive manufacturing solution based on LiM-X series SLM equipment.
As equipment manufacturers compete to enter the market, the application costs are expected to gradually decrease, which will further promote the widespread application of 3D printing of pure copper and copper alloy materials in fields high-end industries such as aerospace, electronics and medical care. However, to achieve breakthroughs on the application side, besides equipment improvement, material development is also a crucial factor.
Taking spherical pure copper powder as an examplewhich has the problem of oxidizing easily. In order to ensure that printed parts have excellent conductivity and good mechanical properties, effective measures must be taken so that they can operate stably in fields requiring extremely high conductivity, such as electronics and electricity. . . This not only extends the life of pure copper components, but also reduces performance degradation and material loss due to oxidation, resulting in significant savings in maintenance and material replacement costs.
To this end, as an innovative company that continues to venture into the field of 3D printing of metal materials,China Sports New MaterialsThe anti-oxidation technology of spherical pure copper powder was launched, which successfully solved the problem of easy oxidation of pure copper powder. This technology forms a stable and effective protective film during the entire process of production, storage, transportation and 3D printing of pure copper powder, strictly controlling the oxygen content to extremely low levels, thus ensuring the high conductivity and the excellent performance of pure copper powder.
At the same time, the AMP production process independently developed by China Sports New Materials has enabled the large-scale production of pure copper powder for 3D printing. Through careful optimization and continuous innovation of the aerosolization process, China Tien New MaterialsAble to stably produce more than ten tons of pure copper powder for 3D printing every monthproviding a reliable supply guarantee for large-scale production.
According to the industry report “Copper Powder for 3D Printing Market” released by market research organization Verifiedmarketreports, the market size of copper powder for 3D printing will reach US$ 850 million in 2022.Expected to reach $2.1 billion by 2030with a compound annual growth rate of 12.1% from 2024 to 2030.
In today’s broad copper powder market, copper alloys have a wider application range, among which copper-chromium-zirconium alloy (CuCrZr) is one of the typical copper alloys with high strength and high conductivity. In this alloy system, the zirconium (Zr) element content plays a key role in the overall performance, which can effectively inhibit grain growth and ensure that the material always has good mechanical strength, hardness and good electrical conductivity in high temperature environments. However, during material processing, the zirconium element burns easily, which makes precise control of the alloy composition ratio a major problem in the industry.
China Sports New Materials has successfully overcome this bottleneck.Development of stable and precise zirconium composition control technologythe zirconium content range is precisely controlled between 0.1% and 1%, and the composition deviation is strictly limited to 0.1%. This precise composition control technology ensures consistent performance of each batch of copper, chromium and zirconium powder, providing a stable material guarantee for industrial applications.
China Sports New MaterialsHigh strength and high conductivity copper-chromium-zirconium alloy powder(CNPC-CuCrZr 15-53μm)
- Fluidity: It has excellent fluidity and the Hall flow rate is less than 20S/50g, which can meet the printing requirements of laser powder bed fusion (LPBF).
- Sintering activity: Good sintering activity gives printed parts high mechanical properties and is suitable for manufacturing high-performance parts.
Sample density test
Test results show that the copper-chromium-zirconium (CuCrZr) alloy powder produced by China Tien New Materials has excellent performance: the average Vickers hardness of the sample is 175.3, and the average density exceeds 99 % tensile strength after heat treatment; reaches 584 MPa, the yield strength is 487 MPa and the elongation is 20%. Currently, China Sports New Materials hasProduce several tons of high-quality copper-chromium-zirconium alloy powder every monthThe stable production capacity can provide the industry with timely and reliable material supply to meet the needs of high-end manufacturing fields.
With the improvement of material properties and process optimization, the application areas of 3D printing of pure copper powders and copper alloys are constantly expanding, showing great potential in multiple manufacturing fields high end:
Aerospace domain
Copper alloy powder for 3D printing can be used to make complex aircraft engine parts and structural parts of satellites. For example:
- Avionics equipment housing: Use the high thermal conductivity of copper alloy to manufacture high-performance heat dissipation components to ensure stable operation of equipment in high temperature environments.
- Satellite antenna structure: Through lightweight design and precise processing, the accuracy and performance of the antenna are improved and the satellite launch costs are reduced.
Automotive manufacturing sector
In automotive manufacturing, 3D printed copper alloy parts can meet the high performance requirements of key components:
- Motor Block and Radiator: The excellent thermal conductivity of copper alloy helps to improve the heat dissipation efficiency of the motor and improve working performance and reliability.
- Brake System: Lightweight, high-strength copper alloy materials help reduce vehicle weight and improve fuel economy and driving performance.
Mold making field
3D printed copper alloy molds bring more possibilities to industrial production:
- Complex cooling channel design: 3D printing can realize the integrated manufacturing of cooling channels and improve the cooling efficiency of the mold.
- Fast heat dissipation: The good thermal conductivity of copper alloy shortens the casting cycle, while improving the lifespan and production efficiency of the mold.
medical field
Customized medical devices are innovative applications of 3D printing of copper alloy materials:
- Implants: Manufacture high-precision joint prostheses, spinal fixators and other implants based on patient anatomy and needs.
- Antibacterial properties: Copper alloy is naturally antibacterial and has good biocompatibility, providing patients with safer treatment effects and a faster recovery experience.
By continuously improving material properties and optimizing manufacturing processes, the application potential of 3D printing of pure copper powders and copper alloys in aerospace, automotive, mold manufacturing and medical will be further released, injecting new vitality into the development of the industry. Looking to the future,Hardware innovation, process optimization and application expansionIt will become the three main drivers to promote the sustainable development of copper alloy powder for 3D printing.
As a leader in the field of powder materials for metal 3D printing, China Sports New Materials plans to continue in-depth research and explore more combinations and ratios of new copper alloy elements, precisely controlling the added amount of alloy elements and the parameters of the surface modification process. continue to improve the laser absorptivity of copper and the forming quality of alloy powder.
At the same time, China Tien New Materials will commit to developing copper alloy materials with higher strength, better electrical and thermal conductivity and greater heat resistance. These innovations will establish a solid material foundation for the application of 3D printed copper alloy parts in more fields and promote technological progress and industrial upgrading.
