December 3, 2024According to the resource libraryDigital IT solutions providerHexagon recently launched a new technology, “Advanced Compensation”, designed to solve the warping problem in the production of precision metal parts and reduce trial, error and time costs. This method combines process simulation and 3D scanning compensation. Using advanced geometric compensation technology, it can automatically correct the deformation of large and complex metal parts during the printing process, to achieve the expected shape.
Improve the precision of metal printing
Laser powder bed fusion (LPBF) technology is currently a commonly used method for 3D printing of metal parts. However, due to the complex physical process involved, this technology presents many challenges in certain industrial applications that require extremely high precision. Particularly in areas such as machine manufacturing, aerospace and medical prosthetics, these industries have strict requirements for surface quality, repeatability and dimensional accuracy of parts. However, dimensional inconsistencies, defects, and deviations produced during the LPBF printing process often affect the quality of the final part, especially in these demanding areas, where any slight deviation may not be acceptable.
To solve these problems, Hexagon’s “advanced compensation” method, based on process simulation and metrology-based compensation technology, helps users achieve high-quality printing when facing thin walls or difficult materials. Through this method, users can control the tolerance between 98% and 100% while ensuring surface contour accuracy, and can improve production efficiency without sacrificing printing speed.
Practical Verification: Improving Accuracy and Reducing Waste
Additive manufacturing company Additive Industries is one of the first companies to adopt this technology and has achieved significant results in its production process. The company successfully printed a stainless steel jet engine exhaust mixer using an “advanced compensation” method with an accuracy of 0.2mm and required only one prototype.
This large 316L steel component has a surface tolerance of +/-0.2mm. Compared to the previous printing process where parts naturally deformed more than 3mm, high-precision construction can be achieved with just one trial print, significantly reducing material waste and printing time, all minimizing support structures.
Provide accurate forecasting and compensation
To ensure the effectiveness of this remuneration method, Hexagon also combines two advanced software tools. Simufact Additive software helps users predict warping and shrinkage through accurate simulation, minimizing the number of trials during the printing process. At the same time, VGSTUDIO MAX software provides powerful 3D scanning metrology and analysis functions, which can handle more complex part characteristics. By scanning the part and obtaining its optical or CT scan data, VGSTUDIO MAX is able to correct local deformation problems by compensating for deviations measured from the scan data.
In addition, the operation of VGSTUDIO MAX is very simple. Even users without previous measurement experience can easily get started and achieve ideal printing results.
Data-Driven Print Optimization
The director of additive strategy at Hexagon highlighted that simulation technology can save time and money when printing complex parts or mass production. When simulation is not enough to resolve all issues, users can use optical 3D scanning to capture defects and compensate for them, thus achieving “second time success”.
He added that this data-driven approach can reduce the uncertainty of small-batch production and scale to large-scale production through digital twin technology, which not only optimizes part geometry, but s It also precisely adjusts based on machine parameters and material properties to ensure parts performance and quality are on point. ShouldSimulation softwareRelease for all Simufact Additive users is planned for the first quarter of 2025.
Conclusion
With the continued development of additive manufacturing technology, how to improve production precision and efficiency and reduce waste has become an industry priority.HexagonThe “Advanced Compensation” approach provides new solutions for the production of precision metal parts thanks to innovative simulation and compensation technology.It not only brings more reliable production methods to industries that demand high precision, but alsoOpening up new possibilities for large-scale additive manufacturing applications.
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