Prodways
Prodways Rapid Additive Forging
Example of 3D printed and partially finish-machinedtitanium part.
Ahead of its appearance at the Paris Air Show next week, Prodways Group has launched its new Rapid Additive Forging (RAF) 3D metal printing technology.
The French company has developed the process for the printing of large titanium parts for critical applications in use of industries, such as aerospace. Prodways partnered with Commercy Robotique, a fellow Groupe Gorge subsidiary who specialised in robotised welding, and has filed a patent for the technology.
Built from a lengthy research and development effort, Rapid Additive Forging uses a robot equipped with a head depositing molten metal in an atmosphere of inert gas layer by layer to build a part within hours. Titanium blanks, which have similar geometry to the final part, are manufactured with RAF and finish-machined, avoiding significant material losses. This excess material can represent 95% of the metal block with traditional manufacturing methods.
As well as solving material-wastage issues, the RAF technology also saves a considerable amount of time in the building of titanium parts. Certain structures have lead times of more than 12 months, but Prodways believe its RAF technology can manufacture parts in a fraction of the time.
So far, the process has been tested on a number of metals, but since titanium continues to be used increasingly in new-generation aircraft, Prodways sees those making parts in the lustrous transition metal as the main beneficiaries. Currently on the third prototype of the technology, RAF can print parts up to 70cm in size. As development resumes, Prodways is looking to print parts of up to two metres in the main dimension.
Rapid Additive Forging uses a distinctive metal deposition technology, focusing on the metallurgical quality and the repeatability of the process. The first metallurgical tests carried out on different parts revealed an absence of porosity, and greater mechanical resistance, compared to other 3D metal printing methods which use laser or electron beam sintering.
Prodways, who will provide regular updates on the development of RAF, has said a number of leading industrial groups have already shown their interest. Representatives from the company will also be present at the Paris Air Show, ready to discuss RAF.
