3D printing End-to-end software chain for better LPBF machining results

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SCANLAB GmbH

AMETEK GmbH Division Creaform Deutschland

AMPCO METAL Deutschland GbmH

Renishaw plc

Scanlab, a key provider of laser scanning systems, introduces its Scanmotion Control software for metal 3D printing, enhancing efficiency and precision. Showcased at Formnext in Frankfurt, this software optimises laser machining trajectories for better part quality.

As a leading supplier of laser scanning systems, Scanlab helps machine builders develop new metal 3D printing systems by providing coordinated solution modules. These include high-quality laser scanning systems and control solutions for efficient laser process development and effective production. Ultra-precise printing results from the Fraunhofer ILT, which can be used on industrial machines with the new Scanmotion Control software, will be presented at Formnext in Frankfurt. Partnerships with renowned software manufacturers ensure seamless integration of the control solution.

At the heart of laser powder bed fusion (LPBF) machines for 3D metal printing are the scanning systems and their interaction with the laser. Scanlab has been a pioneer in the development of scan heads for 3D printing since the 1990s. In addition to the hardware components themselves, control systems have become increasingly important in recent years.

The efficient operation of industrial laser machines in the field of additive manufacturing requires control solutions that cover the entire software landscape, from CAD/CAM to machine software and laser job execution. Scanlab works with leading vendors such as Autodesk, Dyndrite and Siemens in combination with Aixpath to provide integrators with harmonized solution modules. This simplifies system development and significantly reduces time to market for new laser processing machines.

More flexible laser process control and higher part quality

Scanmotion Control, the recently launched control software, synchronises the scan system, laser and other peripherals. The software calculates optimal laser machining trajectories based on predefined machining patterns and process parameters, taking into account the physical limitations of the scan head. The energy input can be precisely defined because the speed and laser power are planned, simulated and adjusted synchronously. Previously, the exact scan path had to be determined through experimentation. With off-line simulation of the trajectories, this can now be checked and optimised on the computer in advance. This gives the process developer full control over the energy input at any point on the part. This makes job planning much simpler and development times much shorter.

Furthermore, by testing the software in additive manufacturing, the experts at Fraunhofer ILT have demonstrated that it is possible to drastically improve the dimensional accuracy of filigree components. “With the use of Scanmotion Control, for example, we were able to avoid edge bulging on complex components — and not just in the lab. Using the software, the results can easily be applied to an industrial scale,” explains Dr. Tobias Pichler, Process & Systems Engineering, Fraunhofer Institute for Laser Technology ILT.

The new software allows users to achieve optimum machining results with minimum laser-off times. The scan systems Fibersys, Excelliscan and Intelliscan IV are ready for Scanmotion Control. By working together with the different software providers, the seamless integration of high-quality components into laser machining systems is ensured.

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