Elmet Technologies is to deploy 3D Systems' DMP Flex 350 Triple metal 3D printing system for the production of hypersonic vehicle parts.
Combining the DMP Flex 350 Triple machine with a high-performance C103 material, Elmet expects to 'rapidly qualify and certify' the system and begin production later this year. C103 is a niobium-based alloy composed primarily of niobium with hafnium and titanium, designed for extreme high-temperature and aerospace applications.
Elmet Technologies has been working with 3D Systems' Application Innovation Group (AIG) for eight years, developing parameters for C103 material specifically for this deployment. AIG engineers consult, guide and assist customers like Elmet with the advanced development of processes and materials. Having come through this partnership, Elmet is now readying to deploy 3D Systems 3D printing technology for the production of large heat exchangers for hypersonic vehicles.
“We collaborated with AIG on the parameter sets for the C103 material,” said Scott Ohm, R&D Manager, Elmet Technologies. “The work was done on an earlier 3D Systems metal 3D printer, and we expect that prior research work will make it very easy to begin production on the DMP 350 Flex Triple.”
The DMP Flex 350 Triple boasts a 350 x 350 x 350 mm build envelope, three lasers, and a low-oxygen environment (<25 ppm oxygen, typically ~0-6 ppm oxygen) that allows for 'exceptional powder reuse rates', tight control of metal chemistry, and superior surface finishes, per 3D Systems.
“This machine, material and process should achieve qualification within a couple of months,” added Ohm. “We anticipate NASA 6030 certification a few months after that. This is very fast and indicative of the quality of this entire solution, as well as confirmation of the sound business case for collaboration 3D Systems’ Aerospace and Defense experts to streamline the qualification and certification process.”
“This collaboration with Elmet is a standout example of using metal additive manufacturing to create new advantages in aerospace design and production,” said Mike Shepard, Vice President of Aerospace & Defense, 3D Systems. “The low oxygen architecture of our DMP series metal additive machines is ideal for manufacture of complex components from highly reactive metals, like C103 and other refractory alloys.”
