I did not know EDM existed until 3 weeks ago, when I started a new job. Our shop has 3 of these, but they operate in the open, not under water. Now I see one (for the first time) on TH-cam. Amazing idea.
Yeah edm is amazing, I've been doing wire eroding and spark erosion (die sinking) for the last 26 years, its old technology but still sometimes its the only way a job can be achieved :)
Back in the mid 80's I worked for a company (Costa Mesa Ca) that machined turbo fans for several different companies. The labor hours for turning and especially milling were staggering. This old guy can really relate and appreciate how far the manufacturing processes have come...
This is clearly the way to go when reverse engineering machine parts to give an even longer life cycle to any manufacturing process. Amazing proof of concept video!!
show us "end user product" - perfectly polished and balanced. also what about structural integrity of such production method? right now this looks like extremely wicked peace of scrap metal that will cost a fortune!
Usually the inner porosity is zero on right settings, atleast the centre line core. surface is typically over built for final machining and includes enough meat to account relaxation too. But it all comes down to the programmers intuition, additive has 100x the variables of subtractive
Looks friggin neat. Could you do some stress tests on a part as thin as that? Also, for a fan I'd imagine the blades would have to be a bit smoother? Are you planning on any other finishing ops?
There are parts you cannot make without seams and gaskets. That's where 3D printing metals really shines... But I am always curious what the real longevity / strength of those parts are.
The major problem being the rough surface finish of the blades which would have a big impact on their efficiency I imagine. You would have to add a third process; some kind of polishing tool on a 5 or 7 axis cnc.
Would kinda defeat the purpose, a tumbling machine with some sort of media would probably do a good enough job of polishing it to a smooth enough surface.
Well Sintering and casting has been around for years, and there's a reason none of those are used for high stress applications. Heat treatment won't help either because you can't cheat yourself to a perfecr cristallyne substructure when it comes to steel and alloy.. Even die cast compared to a milled part will never be as strong. You are basically spotwelding an entire part with metal 3D printing.
Omg... They wouldn't post it if it wasn't AWESOME!!! -The stress tests are better than CNC build- guaranteed: Machining creates stress. + (remember!)That 3D printer is built for this!! With all the steps and labor time spent on machining this piece 'old-school' (! Think about it!), I can't believe how anyone is still skeptical about this process being far superior in so many ways.
It would have been interesting to have a time lapse timer on screen during the EDM phase. A number of people who have never been exposed to the process may not perceive the actual time committed to each process. If possible, show us inspecting the finished part balance; which to me; verifies that the print resolution is sufficient to maintain uniformity through out the entire process. Just for some added dangerous fun and as a durability test: Affix that blade to the previous days spinning top demonstration, spin it up so we can hear it. Maybe add some smoke using a AEROLAB smoke generator for the visuals; similar to devices used in wind tunnel testing. Surely in DFW area, someone would still have them. 😉
EDM is slow. Roug cut on 20-30mm thick steel could be around few mm per minute. Rough cut on 150-200mm will be around 0,5mm per minute and less. Skim cuts (finishing) are faster (up to few mm per minute), but depending on the required tolerance it could require 5 or more skim cuts on very precise features.
@@Stasiek_Zabojca Yep, it's difficult to convey in practical terms that even a child can comprehend. There are many who have no idea that EDM machines have existed for decades or how they affect everyday living.
That, is amazing. If that doesn't make you feel blessed, there's something wrong. I mean, laser cutting is amazing, and even laser cutting isn't ideal to make that kind of part. Even injection molding wouldn't work very well. If that's just a test piece, kudos to whoever ran it in CAD. The curved blades take time to draw. If that really is a job and not a test piece, it's probably an industrial thing that'll get tumble polished before use. That, is cool. Blows the old days of 3D printing out of the water!
🎯 Key Takeaways for quick navigation: 01:14 🛠️ Metal 3D printing allows for the creation of complex parts like the 48-blade fan with ease. 03:18 🧰 To prevent the fan from pulling away during cutting, they use a shim and C-clamp to secure it in place. 04:11 ✂️ Additive manufacturing combined with EDM allows for precise cutting of thin-walled parts like this fan. 04:50 📏 The fan features 48 blades, each 50 thou thick, made from 316L stainless steel, resulting in a lightweight and impressive final product. Made with HARPA AI
An excellent application of 3-D printing technology to obtain three-dimensional metal parts that have some complex shape like a turbine part. But it is obvious that the result is only a raw blank of a part that does not have the necessary mechanical properties of the metal (strength, flexibility, fatigue, etc.) and the necessary service characteristics of the working part itself as a whole. Therefore, further development of this technology and, accordingly, obtaining evidence of its effectiveness is necessary.
I'd like a follow up on this part as from my understanding 3D printed parts don't do so well with fatigue stresses thus I'd like to know how well it did in the field.
"3D printing" is a generic term for many types of additive manufacturing. The process used to make this part could be simplied to say "laser welded". You'll see minor to extreme internal thermal stresses in this manufacturing method. Some parts will have trouble remaining dimensionally stable (depending on the material thickness and part geometry) during thermal reliving. But fatigue failure is not common for this or other types of selective laser melting; However, it is seen in many additive processes that have non-uniform layer density like FDM. The stigma for 3D printing and fatigue failure comes from early 3D printing that was relagated to lactic plastics with little elastic deformation.
For those doubting material integrity of the finished part, I wonder why they think 3D parts made with the right additive chemistry and process cannot go through the same heat treatment and finishing processes that a part made with traditional process goes through.... Even if the manufacturing process itself allows levels of strengthening and work hardening, I wonder why people seem to think that it cannot be replicated. Lots of reputable research suggest it is very much possible and already being done. Is there any reason to believe otherwise?
request/suggestion if you have time: analysis of material properties, print time, and cost vs the original part. also curious about air or fluid flow over that surface.
im not sure how smooth or rough the surface finish is but i can imagine that the efficiency of that fan is not what it could be if it was polished or milled.
All the fancy tec and we still use the trusted G clamp, how long did it take to cut through, Im wire cutting some titanium 3d printed parts and have found the speed is all over the place due to the cavities inside and the way the water blasts ( mines open flush ) but bloody hell 3d prints look good.
Looks super neat for a low volume run but way too expensive in series production. In my option stamping the blades (high volume) or laser cutting (low-mid vol.) and then laser or resistance welding them together would have been the way to go.
I wonder if there are way for you to smooth the surface of those blades without crazy multi axis machining. Perhaps tumbling or some sort of vibration based process? Or may be some chemical deposition of some variety? Also im very curious to see some analytical data comparing the performance, efficiency and other metrics of 3D printed metal part with machined one.
Wondering the same thing. I'm thinking they would put it inside a chamber, and use an abrasive that's sprayed onto the blades by high-pressure nozzles.
OMG I wish I could use those machines for my hobbies! I'd have so much fun inventing stuff also! I love this new technology it's freakin' awesome! Please do more stuff like making jet engine turbine blades, turbo wheels, engine blowers, helical miter gears etc., etc.. 👍BOOM!👊
@@tacomonkey222 Actually no, durability is better than CNC. Parts have ~99,99% density and unique small microstructure yields excellent mechanical properties. Strength is below forged but better than CNC. Surface roughness will have an effect for the fatigue.
@@vn-dc3hv 3D printing doesn't magically add strength to the part. A machined part will be just as strong as a printed part. Assuming the same material is used. In this case 316.
@@brandons9138 it's not magic its metallurgy. Part is built by melting powder with a very small laser, this causes very very rapid melting and cooling which in turn gives very fine and unique grain structure. This microstructure strengthens the metal, especially 316L which you cannot harden by heat treatments. There's really no way to introduce such grain structure into CNC'd part in 316L. Trust me, I did my masters in this exact subject.
Is the surface textured? I'm curious, a rough surface would not be good for air flow. Can you print with smooth surfaces with this machine? That said, this thing is badass! Thanks for sharing. Also, what was total time to make part and the, total time to cut with EDM?
Yes, surface is textured. Feels like parts that have been sand blasted or fine to mild grit sandpaper. You would not bolt two flush surfaces of these printed parts together. Mating surfaces are commonly finish machined. 3D printing methods for tubing applications that require smooth-bored channels are commonly Material Jetting (Polyjet) and SLA or DLP.
From start to finish, what's the cycle time per part? Judging the comments, I believe most are wondering how realistic this process would be in the production world, compared to the more tedious 4 step process. Thoughts? I'm curious myself as I've never been in an environment that does actual industrial 3D printing..the kind outside of small fixture and prototyping.
The problem is that a part like this is EXTREMELY hard to make - look at the holes in the blades, which are trivial in additive, brutal in CNC and other processes. Porsche is using a process like that to make the cylinders for high end sports engines - hollow with a support structure, cnc'ing them to tolerances after print. Price IS an issue, but not necessarily for all parts.... and substractive manufacturing has serious limitations in that you need to be able to get the tool into the area to take parts out. Removing powder is more easy.
@@ThomasTomiczek Thank you for your response. It still blows my mind how far the world of 3D printing has come in the last 5 years! I could see the luxury car brands using this method now that you mention it. Customization is usually prevalent because people buying the exotics can afford it. Makes sense.
@@saram9590 Selective laser melting production applications are for low volume manufacturing on complex geometry parts, and oftern high risk for engineering change. It is also not so new anymore. Enjoy some of my favorite automotive applications from 8 years ago. th-cam.com/video/DNedUZxP8NU/w-d-xo.html th-cam.com/video/Dw6cs7opvzA/w-d-xo.html th-cam.com/video/SRA5CFLYkUQ/w-d-xo.html
nice, we have a trumpf laser and we love it but our company said we wont buy them again cause customer service is horrible. Is it the same with the 3d printers?
Oh god, it's nice; I need to see the structure of this print under a microscope. And I really like to know about printing metal reacts when we polish them.
I suspect the multi-operation build with sheet metal provided for smooth surfaces. What processes can be used to improve the surface finish? Is the roughness due to the metal particle size in the 3D laser printer?
Would you guys, or have you already, recreate the Sabu Schist Disc. It's a tri-lobed bowl 61cm in diameter, with a height of 10cm. I'm curious what it sounds like when spinning at different RPM. I am curious if it makes different sounds as different metals, stainless steel, Ti, Brass, Copper, RPM, etc. Just a curiosity, There are other discs related to it. There's a 5 smaller lobed top disc and another one that's 7, again a topper. I think goes together with the tri-lobed disc. I don't know if it's a propeller, a rope make, musical sound instrument? The only other way I'd like to get it made is with stone but I don't even know who, how or what for that.
Very nice print, clean and smooth, as much as it can using these methods. And now the 1 million dollars question: what are the printing parameters you have used (LASER power, scan speed, hatching, layer thickness, LASER beam moving strategy, did you use contours?) :P
look nice. but what stress can handle and stufs. i mean when you make stainless still it pass at diferent proces to reduce stres or to induce. How the A.D.M deal with that?
I'd be really interested in more info about it as I'm a 3D printing evangelist, teaching about the advantages, this would be a great real-world example. What about a polishing process? Do you have more info about the original part? Time and money savings?
so, instead of a 4 step process you have to: print it (1 step) cut it with a wire EDM ( 1.1 step because you have to add the shims ) somehow polish the blades heat treatment/sintering? it sounds like it has about the same steps (heavily automated, but steps none the less) how do they compared in terms of strength and stiffness against the traditional method?
How thick is the material at the centre of the part when you are parting off with wire EDM... Could you not make a internal fixture to hold from front of the part the cut the support material off... Can wire be orientated horizontal with vertical travel Would save having to stop and clamp, it looked awkward But I really like your work Guys n girls of Titan
If you are a true American company - advertising Made in America you should use US machine manufacturers, and support local products to which you can also contribute.... Use Desktop Metal, the best metal 3D printers, and they are made in America!
there is no freaking way that thing can support the same stresses a properly forged and welded piece woudl, but that doesnt matter, speccially if you could smelt-forge it to get similar results, the fact that it reduces human time requirements its huge enough!
Was there a rough surface finish as appearance in the video? Perhaps not as optimal as formed sheet metal blades as regards smooth flow through the fan? Or perhaps secondary operations were done to smooth the blades? Nice demo.
It's just plain water. An electrolyte is conductive. That would not be good. You want the electricity to be focused at the cut, not over the entire machine. Only a dielectric fluid, like near water, will work. It has a DI system.
Question: To have the best possible airflow, turbine blade surfaces are usually very smooth. Is the rough surface left on these printed blades not an issue then? It would seem to me that it creates turbulence, no? Or is this perhaps just a prototype part and will the production one be made using a different technique? Could someone knowledgeable shed some light on this?
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I did not know EDM existed until 3 weeks ago, when I started a new job. Our shop has 3 of these, but they operate in the open, not under water. Now I see one (for the first time) on TH-cam. Amazing idea.
Edm nothing new. Been out for 50 years!
@@codprawn I’ve heard it was used in some form during WW2
@@Guranga93
Probably
Nothing like an electric wire that vaporizes everything in its path with microscopic lightning bolts
Yeah edm is amazing, I've been doing wire eroding and spark erosion (die sinking) for the last 26 years, its old technology but still sometimes its the only way a job can be achieved :)
Back in the mid 80's I worked for a company (Costa Mesa Ca) that machined turbo fans for several different companies. The labor hours for turning and especially milling were staggering. This old guy can really relate and appreciate how far the manufacturing processes have come...
This type of design and manufacturing is pretty amazing for metal work and it’s application for complex product parts, it’s all just so dope
Love EDM technology and ONA is a leader in developing it. Awesome demonstration of one of the many uses for EDM in any shop.
This is clearly the way to go when reverse engineering machine parts to give an even longer life cycle to any manufacturing process. Amazing proof of concept video!!
But does this turbine even work? With the very rough surface finish is should induce turbulences.
@@christopherbentley6647 Right, because whales and fans totally operate at the same reynolds numbers.
@@RunesLegacy I put dimples in my forehead with a ball peen hammer so I think faster because #GOLFBALL
I don't think it matters on a high pressure fan like this, I'd say smooth finish matters more on a low pressure fan like a wind turbine.
@@oldchap1228 a un 9 de una noche
Thr biggest problem is the blades balance
show us "end user product" - perfectly polished and balanced. also what about structural integrity of such production method? right now this looks like extremely wicked peace of scrap metal that will cost a fortune!
Usually the inner porosity is zero on right settings, atleast the centre line core. surface is typically over built for final machining and includes enough meat to account relaxation too.
But it all comes down to the programmers intuition, additive has 100x the variables of subtractive
Looks friggin neat. Could you do some stress tests on a part as thin as that? Also, for a fan I'd imagine the blades would have to be a bit smoother? Are you planning on any other finishing ops?
Maybe you can print to get a smooth finish? I also wonder why there a holes in the fan blades
@@Julian_Bester
Those holes are actually used for heat dispensing. But I doubt this turbine even work.
give us x rays for that beautiful piece
@@prasannajitpadira9655 yeah i really am curious, is this just a fan for looks? or can it actually be put into an aircraft for use?
@@Tay-ky3fi
Pretty sure it can't be used for an aircraft.
Maybe for some industrial turbo fan ?
There are parts you cannot make without seams and gaskets. That's where 3D printing metals really shines... But I am always curious what the real longevity / strength of those parts are.
Yeah, I wondered that as well. How long will that sucker stay together at 20K RPMs or whatever rate the fan is spinning?
The yield strength is comparable (within a few percent) to bulk castings of the same alloys.
@@jdrevenge Care to provide sources for that? Everything I know about materials science leads me to believe that is very much false.
@@ILoveTinfoilHats Also, that's for ultimate strength, the yield strength of the 3D printed is roughly double, because, well, grain size.
@@jdrevenge Again, sources? You can tell me all you want, but without a reliable resource to back you up it's just warm air to me.
It's great how you share your process for this complex part.
This is a game changer I had no idea that this could be done...now if u need a specific part made its just a click away.
The major problem being the rough surface finish of the blades which would have a big impact on their efficiency I imagine. You would have to add a third process; some kind of polishing tool on a 5 or 7 axis cnc.
Would kinda defeat the purpose, a tumbling machine with some sort of media would probably do a good enough job of polishing it to a smooth enough surface.
Well Sintering and casting has been around for years, and there's a reason none of those are used for high stress applications. Heat treatment won't help either because you can't cheat yourself to a perfecr cristallyne substructure when it comes to steel and alloy..
Even die cast compared to a milled part will never be as strong.
You are basically spotwelding an entire part with metal 3D printing.
So satisfying. I just love all the thoughts that go into manufacturing techniques
Omg... They wouldn't post it if it wasn't AWESOME!!!
-The stress tests are better than CNC build- guaranteed: Machining creates stress.
+ (remember!)That 3D printer is built for this!!
With all the steps and labor time spent on machining this piece 'old-school' (! Think about it!), I can't believe how anyone is still skeptical about this process being far superior in so many ways.
Beautiful one. But I wonder if it might need any further heat treatment and surface treatment prior to the operation?
It would have been interesting to have a time lapse timer on screen during the EDM phase. A number of people who have never been exposed to the process may not perceive the actual time committed to each process.
If possible, show us inspecting the finished part balance; which to me; verifies that the print resolution is sufficient to maintain uniformity through out the entire process.
Just for some added dangerous fun and as a durability test: Affix that blade to the previous days spinning top demonstration, spin it up so we can hear it. Maybe add some smoke using a AEROLAB smoke generator for the visuals; similar to devices used in wind tunnel testing. Surely in DFW area, someone would still have them. 😉
EDM is slow. Roug cut on 20-30mm thick steel could be around few mm per minute. Rough cut on 150-200mm will be around 0,5mm per minute and less. Skim cuts (finishing) are faster (up to few mm per minute), but depending on the required tolerance it could require 5 or more skim cuts on very precise features.
@@Stasiek_Zabojca Yep, it's difficult to convey in practical terms that even a child can comprehend. There are many who have no idea that EDM machines have existed for decades or how they affect everyday living.
That, is amazing. If that doesn't make you feel blessed, there's something wrong.
I mean, laser cutting is amazing, and even laser cutting isn't ideal to make that kind of part. Even injection molding wouldn't work very well.
If that's just a test piece, kudos to whoever ran it in CAD. The curved blades take time to draw. If that really is a job and not a test piece, it's probably an industrial thing that'll get tumble polished before use. That, is cool. Blows the old days of 3D printing out of the water!
Amazing futuristic technology, you will be leading the market. Thanks Titan
🎯 Key Takeaways for quick navigation:
01:14 🛠️ Metal 3D printing allows for the creation of complex parts like the 48-blade fan with ease.
03:18 🧰 To prevent the fan from pulling away during cutting, they use a shim and C-clamp to secure it in place.
04:11 ✂️ Additive manufacturing combined with EDM allows for precise cutting of thin-walled parts like this fan.
04:50 📏 The fan features 48 blades, each 50 thou thick, made from 316L stainless steel, resulting in a lightweight and impressive final product.
Made with HARPA AI
I was totally waiting for this
An excellent application of 3-D printing technology to obtain three-dimensional metal parts that have some complex shape like a turbine part. But it is obvious that the result is only a raw blank of a part that does not have the necessary mechanical properties of the metal (strength, flexibility, fatigue, etc.) and the necessary service characteristics of the working part itself as a whole. Therefore, further development of this technology and, accordingly, obtaining evidence of its effectiveness is necessary.
Muy hermosa,muy limpia en detalles, pero está balanceada?soporta la fuerza centrífuga? Para que sirve?o es solo demostrativa.
AWESOME! Love to see a static and dynamic balance op. Also, real operational temps? Not requiring single crystal high temp blades, obv... Thanks!
Absolutely love it. Amazing how to shorten the Bill of Processes. How long did it took to 3D print the part ? And how long took the wireEDM process ?
I'd like a follow up on this part as from my understanding 3D printed parts don't do so well with fatigue stresses thus I'd like to know how well it did in the field.
Here is how bad they do: th-cam.com/video/RrVRSbc6Oec/w-d-xo.html - porsche printing engine pistons.
"3D printing" is a generic term for many types of additive manufacturing. The process used to make this part could be simplied to say "laser welded". You'll see minor to extreme internal thermal stresses in this manufacturing method. Some parts will have trouble remaining dimensionally stable (depending on the material thickness and part geometry) during thermal reliving. But fatigue failure is not common for this or other types of selective laser melting; However, it is seen in many additive processes that have non-uniform layer density like FDM. The stigma for 3D printing and fatigue failure comes from early 3D printing that was relagated to lactic plastics with little elastic deformation.
Yeah there’s no way it holds up in the field
For those doubting material integrity of the finished part, I wonder why they think 3D parts made with the right additive chemistry and process cannot go through the same heat treatment and finishing processes that a part made with traditional process goes through....
Even if the manufacturing process itself allows levels of strengthening and work hardening, I wonder why people seem to think that it cannot be replicated.
Lots of reputable research suggest it is very much possible and already being done. Is there any reason to believe otherwise?
Because they dont know how traditional process works
Let’s see the parts work in the field then
You can heat treat cast, billet and forged the same way and all will come out differently in strength
request/suggestion if you have time: analysis of material properties, print time, and cost vs the original part. also curious about air or fluid flow over that surface.
im not sure how smooth or rough the surface finish is but i can imagine that the efficiency of that fan is not what it could be if it was polished or milled.
Just incredible what 3d printers are able to do.
All the fancy tec and we still use the trusted G clamp, how long did it take to cut through, Im wire cutting some titanium 3d printed parts and have found the speed is all over the place due to the cavities inside and the way the water blasts ( mines open flush ) but bloody hell 3d prints look good.
I'd love to see the run out on the lathe
In it's raw state it would be horrible. 3D printing cannot come close to the tolerances of machining.
That machine is unbelievable 😳
Looks super neat for a low volume run but way too expensive in series production. In my option stamping the blades (high volume) or laser cutting (low-mid vol.) and then laser or resistance welding them together would have been the way to go.
How do you figure that this is too expensive? We don't know the cost.
@@jdrevenge 3d printing 316L like this would cost up to $0.8/gram. So if your part is 1lb then it may cost $362
I wonder if there are way for you to smooth the surface of those blades without crazy multi axis machining. Perhaps tumbling or some sort of vibration based process? Or may be some chemical deposition of some variety?
Also im very curious to see some analytical data comparing the performance, efficiency and other metrics of 3D printed metal part with machined one.
Wondering the same thing. I'm thinking they would put it inside a chamber, and use an abrasive that's sprayed onto the blades by high-pressure nozzles.
Perfect Gear Wheel,like it~
OMG I wish I could use those machines for my hobbies! I'd have so much fun inventing stuff also! I love this new technology it's freakin' awesome! Please do more stuff like making jet engine turbine blades, turbo wheels, engine blowers, helical miter gears etc., etc.. 👍BOOM!👊
My kids bought me an inexpensive 3D printer (Ender 2 V2) for my birthday last year. This has been the best gift ever for this retired guy...
Absolutely awesome. I wonder about the strength of the part though.
Very very strong high quality metal. There are plenty of stress test online.
koenigsegg uses 3d printed turbo's
love 3d printing so cool to see how far it has come.... wonder how the durability of the 3d printed part would compare to a cnc part
The durability will be less compared to the cnc
My buddy does plastic printing & each layer is basically a weak spot...
@@tacomonkey222 Actually no, durability is better than CNC. Parts have ~99,99% density and unique small microstructure yields excellent mechanical properties. Strength is below forged but better than CNC.
Surface roughness will have an effect for the fatigue.
@@vn-dc3hv 3D printing doesn't magically add strength to the part. A machined part will be just as strong as a printed part. Assuming the same material is used. In this case 316.
@@brandons9138 it's not magic its metallurgy. Part is built by melting powder with a very small laser, this causes very very rapid melting and cooling which in turn gives very fine and unique grain structure. This microstructure strengthens the metal, especially 316L which you cannot harden by heat treatments. There's really no way to introduce such grain structure into CNC'd part in 316L. Trust me, I did my masters in this exact subject.
3d metal printed,Incredible!
Is the surface textured? I'm curious, a rough surface would not be good for air flow. Can you print with smooth surfaces with this machine? That said, this thing is badass! Thanks for sharing. Also, what was total time to make part and the, total time to cut with EDM?
It's probably not perfectly smooth but good enough
It's a rough texture from the printer, but can be smoothed to a good finish with vapour honing/blasting
Yes, surface is textured. Feels like parts that have been sand blasted or fine to mild grit sandpaper. You would not bolt two flush surfaces of these printed parts together. Mating surfaces are commonly finish machined. 3D printing methods for tubing applications that require smooth-bored channels are commonly Material Jetting (Polyjet) and SLA or DLP.
It would be no trouble to make it smooth
but will the part spin really fast without breaking?
From start to finish, what's the cycle time per part?
Judging the comments, I believe most are wondering how realistic this process would be in the production world, compared to the more tedious 4 step process. Thoughts?
I'm curious myself as I've never been in an environment that does actual industrial 3D printing..the kind outside of small fixture and prototyping.
The problem is that a part like this is EXTREMELY hard to make - look at the holes in the blades, which are trivial in additive, brutal in CNC and other processes. Porsche is using a process like that to make the cylinders for high end sports engines - hollow with a support structure, cnc'ing them to tolerances after print. Price IS an issue, but not necessarily for all parts.... and substractive manufacturing has serious limitations in that you need to be able to get the tool into the area to take parts out. Removing powder is more easy.
@@ThomasTomiczek Thank you for your response. It still blows my mind how far the world of 3D printing has come in the last 5 years!
I could see the luxury car brands using this method now that you mention it. Customization is usually prevalent because people buying the exotics can afford it. Makes sense.
@@saram9590 Selective laser melting production applications are for low volume manufacturing on complex geometry parts, and oftern high risk for engineering change. It is also not so new anymore. Enjoy some of my favorite automotive applications from 8 years ago.
th-cam.com/video/DNedUZxP8NU/w-d-xo.html
th-cam.com/video/Dw6cs7opvzA/w-d-xo.html
th-cam.com/video/SRA5CFLYkUQ/w-d-xo.html
Gorgeous piece
nice, we have a trumpf laser and we love it but our company said we wont buy them again cause customer service is horrible. Is it the same with the 3d printers?
I can hardly wait until Fiber laser tech gets to industrial power levels where these kinds of things take an hour rather than 12 or more. Zip zip zip!
I think some Electronic Dance Music as the the background to your Electric Discharge Machining video would have been great! :)
Oh god, it's nice; I need to see the structure of this print under a microscope.
And I really like to know about printing metal reacts when we polish them.
great idea with the shim. i was scratching my head wondering how you were going to get the cut all the way through.
How long start to finish. Looks amazing
Fascinating to see these cutting edge tech. Thank you for bringing it to us. One question, how the remaining is removed from build plate?
How long does the 3D printing take for a job like that? Is it saving the company a lot more money?
A microscope image of a cross section could tell us the true strength of this piece.
mindblowing alien technology
turbines produced using this method (essentially sintered metal powder) are not hot-section certified for aerospace apps. SCDS process is best.
How much time did it take to 3D print it?
I suspect the multi-operation build with sheet metal provided for smooth surfaces. What processes can be used to improve the surface finish? Is the roughness due to the metal particle size in the 3D laser printer?
Finally something to cool my gaming pc 😎😎
Would you guys, or have you already, recreate the Sabu Schist Disc. It's a tri-lobed bowl 61cm in diameter, with a height of 10cm. I'm curious what it sounds like when spinning at different RPM. I am curious if it makes different sounds as different metals, stainless steel, Ti, Brass, Copper, RPM, etc.
Just a curiosity, There are other discs related to it. There's a 5 smaller lobed top disc and another one that's 7, again a topper. I think goes together with the tri-lobed disc. I don't know if it's a propeller, a rope make, musical sound instrument?
The only other way I'd like to get it made is with stone but I don't even know who, how or what for that.
Great video. Just would like to know, what's the total hours do you get the final product done, from printing to edm cut?
a day?
is it balanced ? because I wonder if 3D printing in metal gives a constant density of the material
Very nice!! How do you remove the remaining material from the table after separating the model?
Strange, the next recommended video after this is Williams X-jet, a turbine flying booth for 1 person...🤔
Very nice print, clean and smooth, as much as it can using these methods. And now the 1 million dollars question: what are the printing parameters you have used (LASER power, scan speed, hatching, layer thickness, LASER beam moving strategy, did you use contours?) :P
Most popular 3D machine producer is devolop own parameters. This is big know how
Looks like the blades differed in profile and thickness!
That is next level!
It looks cool but how is the structural integrity?
Nice work. 👍
Cool! What is the print time and cutting time for this piece?
Very nice print super
This is magic!!!
What would be the rpm limits on something like this?
I'd like to know
look nice. but what stress can handle and stufs. i mean when you make stainless still it pass at diferent proces to reduce stres or to induce. How the A.D.M deal with that?
How would you smooth and polish that? With other manufacturing styles you would have a mirror finish before assembly.
Would like to see it in action respectively the scenarios it's build for.
without seeing this part at work I will never ever-ever believe in this. For now I think its just a advertising trick
I'd be really interested in more info about it as I'm a 3D printing evangelist, teaching about the advantages, this would be a great real-world example. What about a polishing process? Do you have more info about the original part? Time and money savings?
thats crazy! how strong is that part ? does it need to be baked or anything?
Good question. I would hazard a guess that 3d printed metal parts are brittle
so, instead of a 4 step process you have to:
print it (1 step)
cut it with a wire EDM ( 1.1 step because you have to add the shims )
somehow polish the blades
heat treatment/sintering?
it sounds like it has about the same steps (heavily automated, but steps none the less)
how do they compared in terms of strength and stiffness against the traditional method?
Can you show the turbine in action because people keep saying it won't work.
How thick is the material at the centre of the part when you are parting off with wire EDM... Could you not make a internal fixture to hold from front of the part the cut the support material off... Can wire be orientated horizontal with vertical travel
Would save having to stop and clamp, it looked awkward
But I really like your work Guys n girls of Titan
What’s the application of this part? How much stress can it take or does it take in day to day operation?
Yes. thinking same. i.e. like can it run in a jet engine for 1,000 hours non stop etc... or is it just for show.
What happens to the build plate? Is it actually reusable? How would you clean it up?
WOW 😲 ITS MAGIC
If you are a true American company - advertising Made in America you should use US machine manufacturers, and support local products to which you can also contribute.... Use Desktop Metal, the best metal 3D printers, and they are made in America!
As an upgrade from my CR10s_Pro and resin printer, do you think I'd be able to fit these two machines in my spare bedroom? ;P
there is no freaking way that thing can support the same stresses a properly forged and welded piece woudl, but that doesnt matter, speccially if you could smelt-forge it to get similar results, the fact that it reduces human time requirements its huge enough!
wouldnt you need to perform some sort of heat treatment to remove residual stresses?
how much time it took to complete?
Wonder if they'll ever improve the surface quality of laser metal printing to remove that "pitted" look.
Was there a rough surface finish as appearance in the video?
Perhaps not as optimal as formed sheet metal blades as regards smooth flow through the fan? Or perhaps secondary operations were done to smooth the blades?
Nice demo.
Good working so nice 🙂😊
How much time to take this process
What capabilities of the Trumpf TruPrint system made you choose that system over other LPBF systems?
Hey Guys WHAT KIND of fluid is used for the EDM??? it cannot be plain water. I assume it's some kind of Electrolyte.
It's just plain water. An electrolyte is conductive. That would not be good. You want the electricity to be focused at the cut, not over the entire machine. Only a dielectric fluid, like near water, will work. It has a DI system.
Do you think you could make a 4 cylinder, or 8 would be awesome. Or just the top end could easily improve flow.
Question: To have the best possible airflow, turbine blade surfaces are usually very smooth. Is the rough surface left on these printed blades not an issue then? It would seem to me that it creates turbulence, no? Or is this perhaps just a prototype part and will the production one be made using a different technique? Could someone knowledgeable shed some light on this?
Is the build plate re useable? Do you just turn off the remaining material?
Yep
Turn, Mill or Grind
Wow Wow Wow
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