What is the capability for printing large-size parts?

The ability to produce large-sized parts through additive manufacturing has expanded significantly, moving beyond the realm of small prototypes to full-scale industrial components. Our capability in this area is designed to meet the demanding requirements of sectors like aerospace, automotive, and energy, where substantial part size is often a critical necessity. We achieve this through a combination of specialized industrial machinery, robust processes, and strategic post-processing techniques.

Large-Format Additive Manufacturing Technologies

We leverage several 3D printing processes specifically suited for large-part production, each offering a unique balance of size, speed, and material properties.

Metal-Based Large-Scale Solutions

For large, high-strength metal components, Directed Energy Deposition (DED) technologies are the forefront solution.

• Directed Energy Deposition: This process is our primary method for large-scale metal parts. Using a focused energy source (laser or electron beam) and wire or powder feedstock, DED can build up structures on a much larger scale than powder bed systems. It is ideal for features such as large structural brackets, industrial tooling, and component repair.

• Wire Arc Additive Manufacturing (WAAM): A subset of DED, WAAM utilizes an electric arc and welding wire, making it exceptionally capable of producing parts measuring several meters in all dimensions. While the surface finish is rougher, it offers unparalleled deposition rates for massive components.

Polymer and Composite Large-Scale Solutions

For large prototypes, tooling, and end-use non-metal parts, we utilize advanced polymer systems.

• Large-Format Material Extrusion: Industrial-grade FDM/FFF machines can produce parts with build volumes exceeding one cubic meter. These systems utilize engineering-grade thermoplastics, such as ABS and PC, to create durable, large-scale fixtures, patterns, and housings.

• Large-Format Powder Bed Fusion: Industrial SLS machines feature sizable build chambers that can produce large batches of nylon parts or single, large components, all with excellent mechanical properties and no need for support structures, which SLS is known for.

Post-Processing for Large Parts

The completion of a large printed part often requires specialized post-processing to ensure dimensional accuracy and functionality.

• CNC Machining: For large metal parts produced via DED, CNC machining is a crucial hybrid step. It is used to achieve tight tolerances and fine surface finishes on critical functional surfaces that are beyond the as-printed capability of the additive process.

• Heat Treatment: Large metal parts are particularly susceptible to residual stress. Controlled thermal cycles are crucial for relieving these stresses, stabilizing the geometry, and achieving the desired mechanical properties throughout the entire component.

• Sandblasting: This is a standard and effective process for cleaning large parts, removing thermal oxides from metal surfaces, and creating a uniform aesthetic finish.

Material Considerations for Large Builds

The choice of material is crucial for the success of a large-scale build, impacting everything from warpage to final strength.

• Metals: We commonly use weldable and stable alloys for large formats, such as Stainless Steel (e.g., 316L) and Titanium Alloy (Ti-6Al-4V), which are well-suited for processes like DED.

• Polymers: For large plastic parts, materials like Nylon (PA) in SLS offer excellent durability and resistance to warping. In FDM, ASA is a popular choice for its UV resistance and structural integrity for outdoor applications.

Industry Applications for Large Parts

Our large-format printing capabilities directly serve industries that operate on a grand scale.

• Aerospace and Aviation: Production of large brackets, ducting, and even structural components for aircraft interiors and satellites.

• Automotive: Manufacturing of custom jigs, fixtures, and full-scale prototyping of body panels and conceptual models.

• Energy and Power: Creating large components for turbines, heat exchangers, and other energy generation equipment.