3D Printing an INSANE Steel Part that's IMPOSSIBLE to Make on a CNC Machine
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- เผยแพร่เมื่อ 30 พ.ย. 2021
- 3D Printing an Impossible Part on the TRUMPF TruPrint 2000.
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#CNC #Machining #Machinist - วิทยาศาสตร์และเทคโนโลยี
Absolutely incredible! This allows us engineers to design much more advanced parts with internal features that previously couldn't be manufactured. This technology is a game-changer. Stronger, lighter, better designs!
Yes less thinking about "how" a design can be made
Yes and no. These machines are awesome, but control over the finished cured size just isn't there. You can't count on a part like that staying within any amount of tolerance less than a few thou at absolute best. I've seen shops have to run a part like that 5-10 times just to get one that was in tolerance. It's super sensitive to laser temperature, layer temperature, powder temperature, etc. Much less the final sintering stages have to be dead on repeatable.
@@BrettFleming I think your point is very important to consider.
3D printing plastic is the same way. Consequently, in my lab, a "tolerance" parameter is used in CAD to attempt to "dial it in".
Any luck in your metal shop attempting a similar procedure?
Imagine having also to build a climate-controlled room to house your already expensive machine!
Process time and scrap rate will change your mind about metal 3d printing. Good for prototyping and rapid iteration. Ask for a lead time on 10000 of what he just made and you will see what I mean. Also no economies of scale so cost doesn't come down much if any at high production volumes.
@@BrettFleming Spot on. Some traditional machining will always be needed but its pretty wild seeing it advance this fast and this much. DMG MORI has a Combo 5-axis Mill with swappable Metal 3D Printing head pretty cool seeing the promo video of it at least. Print, Machine, add more material, then machine that.
Wow! I remember going to see a demonstration of a 3D printer in '94. It made heart valves and they looked kinda rough. To see where this technology has gone is amazing.
Imagine another 20 years...
@@BeastMode-ts6eg Technology brings not progress, but an illusion of progress. On our deathbed, 3D printers cannot help us to get a better next life nor tell us what is our next life going to be like. And yes life does not end with the death of the body, as most Westerners are taught to think.
@@BeastMode-ts6eg Right!? I cannot wait for the new Virus 3D Printer so that a psychopath can print out the Spanish Flu's genome and kill millions! Not to mention 3D printed guns!
Must of been a old powder bed system, the NASA SLA printers back then had pretty high resolution. The guys who created them went on to found stratasys and objet (as well as created the modern STL format)
@@BeastMode-ts6eg Imagine being that poor mf with a 3D printed heart valve from '94
When plastic 3d printing came out I thought that’s cool. But printing with metal, that’s a whole new level👍 I’m 57 now and wish I was 18 again so I could see all of the awesome things that will be created using tech like this over the next 50 years. Simply amazing
I'm skeptical if there are applications beyond prototyping and maybe replacing the odd spare part that can't be found elsewhere. Think of the energy it takes to basically laser weld all of the powder into one part. Traditional methods are still faster and cheaper for mass production.
don't worry, you will live to 107
@@ramdas363 Metallic sintering is used quite a bit in Formula 1 for both Race and Wind tunnel parts, and has been for the past 15 years - In Inconel, Titanium, Aluminium and Maraging steel. But yes, the volumes are far of being considered mass production.
I remember seeing something 3D printed using plastic for the first time years ago, and I remember saying or thinking "this is gonna change the meaning of the word 'printing.'" This kind of technology just keeps getting more and more incredible.
Just imagine having a machine that hasn't had parts made for it in 30 years, you send in the part that needs to be replaced to have a 3D model of it made on a screen, and then it gets printed.
lot of old vehicles are being restored like this!
They are now printing organic material. Within 50 years humans will have access to printed skin. Noses and ears will be the easiest. Bone and organs might take some extra work.
Incredible. Still looking forward to that full depth slot through a china vise 👀 gonna be epic
We purchased the vise😂😂😂
Waiting for it to arrive
@@TITANSofCNC awesome!
Lol that was a great idea, i cant wait
Incredible part design and printer capability! Thanks for sharing.
This is some space age technology and the team you have is just awesome. One word comes to mind: wow!
Been around since the 70's too
@@jonhaze7537 insane when you think about it. Just like the SR-71 reading about the tech in that aircraft to be designed and built back then.
This technology is absolutely mind-blowing! I can't wait to see more videos about the capabilities of this printer!
It is pretty neat. The parent company to the one I work for uses mostly CNC's and screw machines, but back in April they bought a 3d metal printing place. Recently we been getting insert holders with more efficient cooling channels for things like a muratecs, and okumas. Along with a ton of new insert designs. Right now they are just working with tool and die making but planning on more complicated designs for general market to our suppliers our CNC's and screws can't make.
As a one time machinist/tool and die man I have to say, I am AMAZED at the new technology that's come out the past 10 years.
We have printed complex parts like that at work and proem we ran into was getting the powder out of the internal tubes. Flushing with water only made the problem worse. We ended up having to make powder evacuation holes and then plug them once the passage ways were clear. Good luck
Did you try high frequency vibration and an air-blast to fluidize and clear the bulk of the powder?
Ultrasonic cleaning?? 🤔
@@hoping67 sadly didn't work. We ended up having to reprint the part.
@@mattcook9678 oh bummer was it a total redesign or can you write in different steps and galleries??,just out of interest how far do you test the part that's been "printed" what's the typical life expectancy compared to cast parts for instance an exhaust manifold? Also Is the part weldable? Sorry for the questions it's absolutely fascinating
My experience is that this heavily dependent on passage size, and if there are and 'hard' bends. Sub 2.5mm passages seem to have a pretty bad form if they aren't going in roughly perpendicular to the layers. I'm not sure where the cutoff is that a 90 or 180 degree bend can be done without issues as I've never designed anything with big enough passages.
Things have progressed very well since my first exposure to metallic 3D printing in engineering school in the early 2000s. 😁👍
That's just sick, I'm floored by the level of detail....
Looks like they have really stepped up the parts finish since I last saw these in action!
This is the level of 3d printing I expect from Titans of CNC !
Titan, I watch your videos and can't help but dream of doing what you guys do. Keep inspiring us 🤙👌🤜
I just finished designing and building a complex kitchen appliance with a PLA printer, and was blown away by the ability to adjust the design on the fly. Imagine having to make a separate injection mold for each design iteration! It really was fun. But to do it in metal...
Now were talking! DAMN! I made my own DIY Multi metal 3d printer it prints 600x900x135mm, THEN CNC's after that process to tolerance. unlimimited tooling recycling! Love this!
Freaking awesome! I have been into 3d printing as a hobby for years and am just waiting for the costs to come down for a more hobbie style metal printer.
That could take a while, I an thinking $5k or less for "hobbyists" and even that isn't cheap.
I absolutely love that yall are so passionate about this.
BOOM! Looks gorgeous I got plastic beaters for printers. But this makes me want the REAL. Glad I got to view this post in time ❤️
Looks like a heat defuser for a spaceship anyway designs like this is one of the reasons I got into 3D printing
Great to see this stuff 😎👍 keep up the good work 🙂
I love the freedom of creativity that 3D printing gives us.
I am truly amazed this is like getting to ultimate use of technologies for unbelievable advantages
How strong are parts form printing ? For example 10mm pipe form printer and same pipe right from nearest store will have same strenght ? Part you have there is amazing and i'm blown away. Absolutely impossible to make in traditional way.
The 3d printed wont be as strong
SLM printed parts typically have a martensite grain structure, not sure with this machine in particular since it's "multi-laser"
The difference heavily depends on the materials.
For steel the best 3D printed material is a lot weaker than what can be produces by other means (single crystal steel for aviation), on other materials their characteristics are near identical.
Makes the octopus look old school
WoW what's next it's all evolving FAST, Titan keep on keeping on
Mind - BLOWN!!!!!!! The small scale surprised me, but that is only a matter of scale.
Amazing how far everything has come over the last 10 year 👏👏🤟👊
Awesome! As an additive process, 3D printing is perfect, but I still think it will take a long time to completely reduce costs. CNC machining is still an important way to maintain costs.
The key benefit to 3D printing is a near-complete freedom of design. Additive manufacturing enables you to produce shapes that are simply impossible with conventional CNC methods. Cost isn't the main issue. If that better shape creates a superior product, then the increased production cost can be worth it.
Example: Companies are now 3D printing injection moulding dies with conformal cooling channels, so cooling channels that closely follow the injection cavity. The example I saw had a cooling time of 5 seconds before part ejection. The conventional injection mould for the same part required 30 seconds of active cooling before ejection. Chopping 25 seconds of the cycle time is *HUGE* so the one-time extra production cost over conventional CNC parts is accepted without any issue.
I've seen a 3D printed elbow joint for a concrete pumping setup. It was 10x the price of a conventional cast and machined part. But the prototype had been in service for 11 months straight, where the conventional part had to be replaced every 6 weaks because of wear. The AM part was much more shape-optimized so it would 1) last much longer and 2) cause a lot less down-time. Again, production cost isn't the primary concern.
GE did a clean-sheet design of a new turbofan for the Cesna Denali, their new Catalyst engine. That new engine is lighter, more fuel efficient _and_ more powerful, thanks to 3D printing. They consolidated what traditionally would require some 800 separate components into *12* printed parts. Assembly is much easer, and much less fault-prone, the number of parts that require stocking is massively reduced, etc. Again: if additive manufacturing is more expensive than CNC (and it most definitely is!) then there are several ways to offset this with other benefits. But you really need clean-sheet designs for this to really pay off.
You're absolutely correct, but in 20-30 years this technology will have probably advanced enough to give it the edge over CNC even cost wise. I love the possibilities it opens.
Right now, I think the technology is best used as a prototyping device - you can work through a large number of iterations much more quickly and once you're settled on a finalized part, then you can move to traditional manufacturing methods to bring the per piece costs down.
@@bobdole4916 The biggest benefit of additive manufacturing is the near-complete freedom of design.
Sure, it's great for prototyping of parts that can be produced conventionally, but its real advantage is that you can create shapes that are otherwise simply impossible to produce.
That allows for new levels of weight saving, for new levels of parts integration, for new levels of shape optimisation, and so on.
The new GE Catalyst turbofan engine? Complete clean-sheet design, made by additive manufacturing: lighter, more fuel efficient _and_ more powerful, and some 800 components consolidated into just 12. Will be available in the single prop new Cesna Denali. Prototyping you say?
Condolences by the way, for your namesake.
@@Hydrazine1000 I hadn't considered products that would have a low production quantity - very good point.
I mean - yes, this EXACT part is not possible to produce with other methods. You'd need to make it at least 3-parts with normal methods, but those are then also way faster and cheaper for larger production scale - and for nearly anything you want to actually produce that will make 3D printing not an option for scale production.
But it is a great tool for research and small-scale production.
Wow, this is incredible! As a technology enthusiast, I'm blown away by the capabilities of this industrial 3D printer. The fact that it can print fully formed complex metal parts is mind-boggling, and I can only imagine the possibilities this opens up for multiple industries. The level of precision and detail is remarkable, and it's amazing to see how far 3D printing technology has come. I can't wait to see how this innovation will revolutionize the manufacturing world and beyond. Great video, thanks for sharing!
i made chatgpt write that for me.
I'm so excited to see where additive manufacturing is going, take a look at some of the heat exchanger designs using triply periodic minimal surfaces that are being designed, it's changing the way we can think about designing from, best compromise to best theoretical solution.
For Raptors? 🤔
Would have liked to know how long it took to print.
17 years
Holy cow! That is absolutely AMAZING!
Almost Home shop ready!! For the small R&D and Design Labs!! Thanks guys, great video.
Very interesting. I’d like to see what would happen if you dropped it on the floor. Part of me thinks it will shatter like porcelain vase. I’m curious, so please drop it and let’s see what happens.
Metal printed parts have nearly the same properties as their cast counterparts. Usually around 95% if I recall. Should be as strong as a cast or milled part for most intents and purposes
It will dent or bend at the impacted area instead of shatter
@@PrintsandProps I’m not sure they are quite at that level, especially in fatigue properties
It’s very impressive though
Given that it's 316L and that it's a selective laser melting (SLM) printer, you're looking at 99,5% density or better. It will sit between cast 316L in terms of strenght, and billet 316L. The grain size will be better than as-cast, but it will not (yet) meet properties of forged 316L. Given that 316L is highly ductile, it will dent or bend, depending from the drop height and angle of impact.
But it all depends on the printing method: the laser power, the spot size, the scanning pattern, single melting or remelting, layer height, the powder quality, and so on.
@@PrintsandProps See my other reply: properties depend on a lot of factors. Selective laser sintering (SLS) can get up to 95% density, Selective Laser Melting (SLM) which this TRUMP printer does, can surpass 99,5% density. 3D printed parts can exceed as-cast properties, getting close to forged billet.
Can't wait till we get similar capabilities in our home 3D printers at affordable costs. That would be a game changer!
Never happen. You need to MELT/FUSE metal. That is never going to be cheap.
@@shooter7a that what they said in 1890 for car. Horse will always be faster and cheaper..
@@yanicktanguay2746 uh...sorry but that is a terrible analogy. Do you have any science or engineering knowledge at all? There is this thing called Enthalpy of Fusion that you would know about if you could pass a college level science class. It takes a LOT of energy to change the phase of a metal from solid to liquid so it will fuse. Energy costs. And the components to handle and transform lots of energy cost lots of money. Advancements in technology can not change the laws of physics and thermodynamics.
@@shooter7a no I'm not a master or any scientific. But I'm only a student of 25 y/o I bet in 75 years. We will discovert many way to produce energy, maybe solar, hydrogen, nuclear...
@@yanicktanguay2746 Cars are getting more and more expensive.
If you need to go to the early 1900s to make that point, is it really a solid point?
How do you even model something that advanced, absolutly amazing
it has the precision of a todler drawing a circle. Great
I was wondering, how smooth are the printed surfaces? Since this part will be transporting a fluid through its tubes, I wonder if the surface left by the printer increases drag and turbulences
Because this is a heat transfer component I think the turbulence and increased surface area would be net positive. Based on how narrow the tubes are I would guess that pressure loss isn't something they are concerned about.
The surface finish is half the diameter of the particles, so pretty rough. Maybe 800 grit sandpaper. After looking it up the particles are around 30 micron.
@@d3m0n54in7 thanks
The surface finish almost certainly does increase resistance, but 3D printing lets you reduce the size of the component so much that you often end up with lower overall drag.
@@JamesSeedorf I mean... valid point but I wasn't really wondering the efficency for that particular application.
Rather in general for fluid transportation.
I guess I should have phrased my question a bit differently^^
Neat, but it still has many limitations. I can't imagine the flow-rate for fluid lines being terribly healthy with such a rough surface. Pressure and stress-concentration limits are likely to suffer quite a bit as well.
I can imagine that the more complicated the part, the more surface finishing is sure to be quite the new and challenging conundrum.
If stuff flows thru it, can you not sandblast the interior? With like, probing lines similar to those plumbing cameras or laproscopy tools?
The material removal won't be uniform and will concentrate on points and areas like the outer side of a bend. Even an abrasive line that can be used both in tensing and compression has limits.
And when dealing with high stress/pressure , any rough, sharp feature can became a focus for stress concentration and shearing/fracturing. Very smooth surfaces are necessary if you're working near the limits of a material.
@@FiltyIncognito might be true for pressure applications but then Porsche already used this tech for pistons years ago. In series production. Sure it's not perfect yet but especially for the automotive industry it can replace casting completely. Have you ever seen water channels in an engine block to be sanded or polished after casting
Honestly, I'm not sure how to succinctly reply. It'd be easier to just hand you a textbook on manufacturing processes.
The limitations of 3D printing are well documented.
It's a great publicity stunt, though.
@@FiltyIncognito im sure everyone who made breakthroughs and innovations only followed textbooks.
If you understand engineering then you can understand improvements in tech, for now it's amazing. But it's not meant to replace other forms of manufacturing, just offer another option. If it can make impossible parts, even if not at peak efficiency, that sounds like a big win. Fine tuning and tech will get it to where it's most likely one day a major manufacturing process. I'd imagine it does have limitations, but doesn't everything?
Did you also get feedback from your client on the effect of surface quality on the flow of the fluids?
As beautiful as this is (seriously) the surface still looks a bit like 180 grit sandpaper.
But as always, thanks for sharing. You guys rock
Truly amazing, but I do have one question, do parts like that need any sort of annealing or post heat treatment? I would think that it would be like welding layer after layer, I just sometimes think about sintering sort of effect,possibly due to appearance of outsides. I also am aware that it is 316L SS, which wouldn't need annealing and hardening after, but what about other materials like high carbon steels? Awesome result, and amazing tech. Thanks for showing us.
PLEASE TELL US HOW LONG IT WAS PRINTED? WHAT'S HARDNESS?
It’s like the material that you print with so if this was 316 it would be soft. We run 17/4 so you can heat treat it after and it gets “hard”
is the powder filtered and directly reused? in what percentage reused? how many times can it be reused?
In these types of machines the powder is re used. Nearly 100% of the powder is recoverable
I think the powder going bad issue is a thermoplastic thing
Mazak has an amazing line of conversational subtractive / additive hybrid machine.
This is absolutely INSANE!!! I've been using resin printing for a while, but metal?!?!?!?!?!? Incredible!!!
How was the powder removal from those channels? And how did you arrive at Trumpf as your laser powder bed machine of choice?
So, do I assume correctly that this is a test-print with an opening in the side to showcase the innards? Because for a functioning part, that side opening doesn't make sense at all.
Likely a show piece yes
Came to ask the same thing, it must be a show piece to display the internal structure.
well I guess if you want to see if the internals turn out OK, you need to have a window in one first before you go making the real part.
Funnily enough I once got to do a placement at a Trumpf factory in Germany for a scool project... and man these machines are insane!
Great work as always.
This part looks 'designed to look cool' more than it being designed to be the best part for a given application.
Do the curved heat exchanger tubes really add anything of value?
Not to mention the opening on the side...?
I guess being curved, they have extra length,hence extra surface for heat exchange
it's not even a heat exchanger large flanges on the side for coolant to be passed through would make sense . but it's really just a useless part that looks cool until you ask yourself WTF is that for.
What kind of print time is that? and what would each part cost? I have to imagine it's a lot
It won't be cheap, but if there is no viable manufacturing alternative then you have to pay the price. I'm sure costs will come down as this becomes more mainstream.
Just as a best eyeballed guesstimate from someone that does this, you're probably looking at 2-3 days to print then another few hours to cut that off the build plate if that's all you want to do (there is often some post-processing depending on your needs). With just that, I'd say maybe around $10k.
Salute to the minds of these scholars
It would be interesting to see finishing the ports, turn the faces and finishing the printed thread diameter. Like anyone else who is bit skeptical of the costly process, but also curious would like to see more detail in bond porosity, resolution control and consumable rates. Does the machine log the gas consumed to maintain the work envelope?
Can't wait until metal 3d printing can become useable for home use.
Neat part but completely wrong machine for it. The liquid jacket is completely non-functional and you can't print it functional because it would just encapsulate the powder. This part should have been made on a direct laser deposition machine and not an SLS.
It has ports for the heat exchange fluid, so you could get the powder out of those.
@@Vel0cir you could get most powder out but there's still plenty of powder left in there to contaminate your cooling system and depending on which pump is used, completely destroy it.
I am wondering tho: how good is the surface roughness on the inside of these tubes when printed? I can understand that will heavily affect you pressure losses within those channels.
Jaw dropping stuff...and the music; right out of Terminator. There's no stopping it.
Let's put it this way, the machine is great, the technology is great, but cut the crappy "music" like you are trying to build suspense, it ain't happening. It is false, fake, and definitely overblown. The part itself is enough.
Very American
i havent even watched the video and i already agree with you
Some of us LIKE it. It's appropriate to the feeling we have when watching it.
I love the whole powder bed process, the layering, the way the product is revealed and the surface finish...wow
That's incredible. The things were able to do now with this 3D print/AI technology is the next generation level of precision. Just wow
That looks familiar. Looks good, i like it. Its nice to see nature in engineering.
this is remarkable, i wonder how many differing metallurgical techniques can be applied to this.
Great printing! Can you print the threads? Up to what dimensions?
1:13 exactly what I said. Outstanding machine right there and some excellent work guys
Fascinating. Truly fascinating.
QUESTION: I have been searching for information on the heat treatment of 3D printed metals, hardening of steel to be exact, and have not found much on the matter. Can these components be heat treated after printing? Thanks in advance.
since you have the cutaway put in, you should check for leaks in a way thats easy for viewers to see. You can fill that center bit with liquid and apply a pressure and see if any bubbles come up.
I would love to have one of those machines in my garage!
Awesome! The company I work for could out this machine to use! Showing this video to my boss
Trumpf - German company. I think the 3d metal print technology is by a Italian company they bought
Structural integrity of sand castle. Great.
Insane!! Huge game changer.
Wow. This is amazing. Do you guys print out individual projects on request ?
Your 3d printing is perfect
thats amazing this 3d printing machines.
i just bought my first 3d printer... it's nothing much but I love the ability of converting 3d picture into an actual physial object i can touch
that is cool asf and thats an understatement
Amazed with the shape you achieved! I am wondering just one thing, which treatment do you use to reduce the rugosity of the internal side of the pipes?
i wonder the same, looks a bit rough
Extrusion honing would probably be the best
Nice, I really like trumpf machines, I do cam on a trupunch, it’s a very versatile machine
Phenomenal indeed!! I want one!
I absolutely amazed
simply amazing...
omg the 3m full head resp lol had to wear this for years at my old job in electroplating hate them lol
That is one awesome looking part.
Technology you gotta love it pretty damn amazing👍🏼🤩
Outstanding!
With this tech and others 3d printing in space is not impossible with any part now. This is amazing. Ever since i heard of 3d printing i had always had that lingering question. How do u 3d print metal. This is awsome. Super impressive.
And this is just one of _several_ methods of direct metal printing. There are powder bed methods and powder spraying methods. There are also wire-based methods. Heating sources can be laser, electron beam, arc or electrical resistance.
And then there is indirect metal printing, with metal powder and a binder, which can be jetted or printed from filament, which needs de-binding and sintering as post-process.
Really there is _so much_ going on in Additive Manufacturing, it's mesmerising!
Sounds like each meathod could be better for diffrent parts.
@@jacobanderson6551 Bingo! Powder bed = small build volume, high resolution, low kg/hour build rates. Wire methods = large size, low resolution, high kg/hour build rates. (The Dutch company MX3D printed an award winning pedestrian bridge spanning over 12 m using Wire Arc Additive Manufacturing!) Powder spraying methods sit in the middle ground.
And powder+binder followed by debinding+sintering has its own drawbacks but is much better suited for higher parts count production.
THANKS!
That part is so alien looking!
WOW 👏 CANT WAIT TO SEE MORE!
This is awesome! Bring raw materials to space, 3d parts to build space stations, spaceships, just about anything.
I just hope manufacturers don't start using this method to create pieces that are impossible to service!
Great job on the print!
That's the whole perpus of doing it
You have to buy new.
It's a disposable world now.
Incredible!
This is so awesome
2:25 what about realibility? i mean no need to be hardened or sinterized? i mean heat preparation to reduce stress ... that kind of thing we have to make to nowday materials. Or it can be used right from 3D print?
Wow 👏 incredible !
I bet there have been a lot of changes in two years. This is fascinating.
Looks great