Metal Casting 3D Printers

Tool-Less Wax And Resin Casting Pattern Production

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Overview

In the rapidly evolving business world, you need a 3D printer that puts you ahead of the competition. Intech Additive printers offer transformative advantages at every phase of creation – from initial concept design to the production of final products. The most important step is to ensure you identify the best 3D printer technology for your application.

Which 3D Printer is Best for You? Identifying your unique requirements within the entire design-to-manufacture process will help you select the best 3D printing technology and optimize its benefits.

3D Printing Performance Criteria You Need to Review

  • File-to-Finished Part Speed– Every 3D printer has a different file-to-finished part speed, which takes into account build preparation, print speed, required post-processing, and optional finishing time.
  • Part Strength- Will the parts you print do what you need them to do? This guide will help you review 3D printers that will create parts with the specific mechanical properties your application requires.
  • Accuracy- Accuracy, precision, and repeatability are dependent on a variety of factors including part size, material, geometry, post-processing, print orientation, and more. The Buyer’s Guide helps you define your application accuracy requirements so 3D Systems’ experts can help you choose the right 3D printer at the right price.
  • Material Properties- Understanding the intended applications and the needed material characteristics is important in selecting the best 3D printer for your needs. Each technology has strengths and weaknesses that need to be factored in
  • Part Aesthetics– Some applications require printed parts that are visually appealing, full color, or have specific look and feel requirements. Other applications are purely functional, and part appearance doesn’t matter as long as the parts perform as expected. Use the guide to help determine exactly what is most important to you and review which 3D printers are the best for your requirements.
  • Print Capacity- Required print capacity for production is determined by a variety of criteria including the printer’s ability to make the breadth of the parts you need to create.
  • Initial investment and total cost of operation- The Buyer’s Guide will also help you prioritize what’s more important to you right now: a low cost of entry so that you can learn how 3D printing will benefit your business, or, if you already know how additive manufacturing can be leveraged for your business, a higher initial investment that will result in a lower total cost of operation.

Systems and Equipments

ifusion-sf1

iFusion SF1

The iFusion SF1 Metal 3D Printer is based on Powder Bed Fusion (PBF) technology. Over 30,000 man-hours of Innovation and R & D have gone into its development.
With the unique combination of a 500 Watt Laser and a larger build chamber in its class, it is a game changer and meets the requirements of entry and mid-level component manufacturers.

Key Features

  • High build rate for cost effective manufacturing
    The iFusion SF1 offers unparalleled power with a highest-in-class 500 Watt laser source, allowing one to print with higher layer thicknesses and build rates.
  • Precise & Reliable
    At the heart of the iFusion SF1 Metal 3D Printer are recognized industry gold standard components like IPG lasers, ScanLab optics and Beckhoff automation – which deliver unmatched performance, high precision, and a high degree of stability and reliability.
  • Integrated Software
    The SF1 offers ‘AMBuilder’ an integrated pre-build design software for Powder Bed Fusion (PBF) based additive manufacturing. AMBuilder caters to the needs of both beginners and advanced users.
  • Truly Customizable Parameters
    Intech’s ‘AMOptoMet’ parameter optimization software is available as an option with the SF1. It provides the optimum process parameters to obtain a better surface finish or desired mechanical properties. It reduces the time for the Design of Experiments (DOE) while developing new materials.
  • Value for money
    Intech SF1 Metal 3D Printer is designed, developed, and manufactured in India. The unique combination of a higher powered IPG laser of 500 Watts, a larger build area and a factory configurable laser focus diameter, enables users to efficiently manufacture multiple fine-featured dental components as well as larger cranial/hip implants or aerospace and automotive parts.
iFusion MF

iFusion MF

iFusion MF an advanced Metal 3D Printing system, enables quick adoption of the AM ecosystem. It is an indigenously designed and developed one-of-a-kind Mid Format Laser Powder Bed Fusion (LPBF) Metal 3D Printer. Imbibed with gold standard IPG Lasers, ScanLab Optics and Beckhoff Automation, iFusion MF enables OEMs to seamlessly transition into Additive Manufacturing.

Key Features:

  • Highest-In-Class Laser Power
    The iFusion MF series of printers come in single or multi laser configurations with full-field scanning. Each Yb-Fibre laser is 500W or higher which allows you to build with a higher layer thickness.
  • Largest-In-Class Build Size
    Build Volume of 325mm x 325mm x 420mm,iFusion MF has one of the largest-in-class build envelopes. This allows for printing of a wide range of small to mid-size fully functional components.
  • More Parts-per-Build
    More parts can be nested and stacked during a single build, thereby efficiently increasing the productivity of the print process.
  • Optimized Cost-per-Part (CPP)
    The iFusion MF is designed to achieve competitive Machine Hour Rate (MHR) with optimized cost-per-part (CPP), to match conventional manufacturing processes.
  • Automation of Processes
    For increased operational efficiency, powder handling, powder sieving, and part removal are fully automated in iFusion MF.
  • Easy to Print with a wide range of Materials
    iFusion MF enables the production of highly precise and high-quality printed parts with a wide range of materials and metal alloy powders such as Aluminium, Titanium, Copper, Inconel, Maraging Steel, Stainless Steel and more.
ifusion LF1

iFusion LF

The iFusion LF is designed for industrial applications offers a large build volume of 450mm x 450mm x 450mm combined with lasers for higher productivity. The iFusion LF comes with laser integration from 500W laser and up-gradable to 700W and 1000W. It is specifically designed to meet the industry need from single laser to quad laser.

Key Features

  • High build rate for cost effective manufacturing
    The LF1 has a powerful single laser 500W / 700W / 1000W options, which means you can build with a higher layer thickness, greater throughput, and work with a wider range of alloys.
  • Truly Customizable Parameters on the fly
    Optional software AMOptoMet provides the optimum print parameters for the part – be it print speed, part density, or surface finish, besides creating parameters for new materials on the fly to “Get it right the first time”.
  • Highest in Class Build Size
    With a highest-in-class build size of 450mmX450mmX450mm, more parts can be nested and stacked in a single run, increasing productivity, and reducing your per part cost.
  • Easy to Print with a wide range of materials
    Established Parameters for Aluminium, Cobalt Chrome, Stainless steel, Maraging steel, Titanium, and Inconel alloys are available. Additional parameters can be made available on request.
  • Integrated Software for Build Preparation
    Intech’s own AMBuilder build preparation software which is integrated with the system takes full advantage of the LF1 hardware capabilities. It provides auto orientation, distortion control, and intelligent support selection.
  • Value for Money
    The LF1 is ‘Made in India” and can be bought in rupees avoiding additional customs, freight and insurance costs. Prompt support is provided by our trained  engineers with locally available spares.

 

Applications

iFusion SF1

Aerospace Industry

In the Aerospace sector, additive manufacturing is often used for producing light weight, strong aerospace parts like fuel nozzles and turbine blades.

Automotive Industry

It combines additive manufacturing and simulation to create prototypes that can be tested for form, fit and performance. Parts like intake manifold, fuel pumps, flow control valves, lamp parts, and mirror moulds are developed using additive manufacturing.

Dental Industry

It employs additive manufacturing for producing customised crowns, bridge implants, and complete/partial dentures made to patient-specific requirements. It enables generation of precise and smooth surfaces with minimal post-processing.

Medical & Healthcare Industry

The orthopaedics and medical industry demand high-precision, perfectly fitting, patient-specific customized implants like Implants for joints (Titanium cups for hip and knee implants), Cranio-Maxillofacial implants, Implantable heart valves and Rib cages.

Academic, Universities and R&D institutes

The iFusion SF1 is a perfect fit for Universities and R & D institutes carrying out instruction and research in rapid prototyping and additive manufacturing. SF1’s optional AMOptoMet opens up print parameter generation by allowing new parameters to be developed to print with customized alloys or develop new ones.

iFusion LF

Aerospace Industry

Additive manufacturing enables the production of parts which are of lower weight, complex geometric designs, while meeting the same strength requirements as parts manufactured by conventional means. Additive manufacturing enables the production of parts which are of lower weight, complex geometric designs, while meeting the same strength requirements as parts manufactured by conventional means.

Automotive Industry

It combines additive manufacturing and simulation to create prototypes that can be tested for form, fit and performance. Parts like intake manifold, fuel pumps, flow control valves, lamp parts, and mirror moulds are developed using additive manufacturing. This results in lower initial investment, shortens the development phase of the product life cycle, and enables a faster time-to-market for new models.

Tool and Die

While once the industry was restricted by limitations like simple cooling solutions by drilling in straight lines, Additive Manufacturing now enables Conformal Cooling Solutions where complex free-form internal channels to provide optimum cooling and tempering solutions. This offers various benefits like minimal war page and reduced cycle time, and hence, results in better quality parts produced in a shorter time.

General Engineering

Additive Manufacturing provides industrial companies with completely new solutions for realizing tool-less production methods. The technology gives designers maximum freedom of design. Providing material only where it is needed for mechanical strength or functionality, this solution can also manufacture lightweight parts with highly complex geometries. Equipped with tools to transform design based on functionality, Additive Manufacturing has already set on the path to transform the entire General Engineering Industry.

iFusion MF

Aerospace Industry

Additive manufacturing enables the production of parts which are of lower weight, complex geometric designs, while meeting the same strength requirements as parts manufactured by conventional means. Additive manufacturing enables the production of parts which are of lower weight, complex geometric designs, while meeting the same strength requirements as parts manufactured by conventional means.

Automotive Industry

It combines additive manufacturing and simulation to create prototypes that can be tested for form, fit and performance. Parts like intake manifold, fuel pumps, flow control valves, lamp parts, and mirror moulds are developed using additive manufacturing. This results in lower initial investment, shortens the development phase of the product life cycle, and enables a faster time-to-market for new models.

Tool and Die

While once the industry was restricted by limitations like simple cooling solutions by drilling in straight lines, Additive Manufacturing now enables Conformal Cooling Solutions where complex free-form internal channels to provide optimum cooling and tempering solutions. This offers various benefits like minimal war page and reduced cycle time, and hence, results in better quality parts produced in a shorter time.

General Engineering

Additive Manufacturing provides industrial companies with completely new solutions for realizing tool-less production methods. The technology gives designers maximum freedom of design. Providing material only where it is needed for mechanical strength or functionality, this solution can also manufacture lightweight parts with highly complex geometries. Equipped with tools to transform design based on functionality, Additive Manufacturing has already set on the path to transform the entire General Engineering Industry.

Dental & Medical

It employs additive manufacturing for producing customised crowns, bridge implants, and complete/partial dentures made to patient-specific requirements. It enables generation of precise and smooth surfaces with minimal post-processing.

Research & Development

The iFusion MF is a perfect fit for R & D institutes carrying out instruction and research in rapid prototyping and additive manufacturing. SF1’s optional AMOptoMet opens up print parameter generation by allowing new parameters to be developed to print with customized alloys or develop new ones.

Education

The iFusion MF is a perfect fit for Universities carrying out instruction and research in rapid prototyping and additive manufacturing. SF1’s optional AMOptoMet opens up print parameter generation by allowing new parameters to be developed to print with customized alloys or develop new ones.