Metal Components

Optomec's industry-leading LENS systems are used to cost-effectively fabricate, enhance, and repair high-performance metal components in state-of-the-art materials such as titanium, stainless steel, and Inconel®. LENS 3D printing solutions can be used throughout the entire product lifecycle for applications including repair, rework, coating, materials discovery and hybrid manufacturing. With the use of a high power laser, process controls and complete environmental control, the LENS system can process many high-performance metals including titanium and nickel-base superalloys with the quality required for critical applications. Due to the nature of the process, a high degree of control and process capability is possible.

Repair

The repair of high-value metal components is essential for maximizing part lifetime, reducing operating costs, and helping maintain a high level of readiness. Repair methods that add material to worn or damaged areas require exceptional process control and outstanding material quality. LENS 3D printing systems use energy from a high-power laser to build up structures one layer at a time directly from powdered metals. The resulting repairs have mechanical properties that can be equivalent or even superior to wrought materials. The ability of the LENS system to add material to existing components makes it an essential system for service and repair applications. The LENS manufacturing process has been optimized for repair of DoD and aerospace components. It is currently in use repairing components at service bureau and overhaul facilities around the world. For more information, click here to download a data sheet on "LENS Component Repair"

Blisk Repair

To repair a blisk airfoil, there are several possible approaches, including whole-blade-replacement, blending, or material addition to a cut-out section. LENS offers several advantages that make it an attractive process for material addition. The LENS process provides a very focused, intense source of energy - little of the energy entering the part is wasted, and thus the heat-affected zone is typically much smaller than other processes. The localized nature of the process also means that, by using a hatching back-and-forth pattern, three dimensional shapes can be built up - the process is not limited to just building thin walls, or laser cladding wide areas. Because of the low heat input, the part is less distorted by laser deposition than other processes. The flexibility of the LENS process means that repairs can be made into confined spaces, onto very thin leading edges, and easily fill in a variety of damage. The LENS 3D printing system can process a wide variety of materials, including Ti-6-4, Inconel® 718, and many others. The rapid cooling that the laser beam allows can lead to the generation of desirable microstructures, giving improved mechanical properties over other techniques. The relatively localized laser beam used in the LENS process adds less extra material, requiring less post-deposition machining. For more information, click here to download a data sheet with case study on "LENS IBR/Blisk Repair."

Medical Implants

Medical device manufacturing is a regulated industry in which specialty metals are used for the production of high-performance components. With its costs and time advantages, LENS is an ideal solution for applications including the development, prototyping and production of specialty surgical instruments and orthopedic implants, such as hip, knee and spinal devices. LENS 3D printers can be used to manufacture medical devices with a range of functional enhancements. Current developments include surface coatings for improved wear resistance, and surface texturing for improved integration with native tissue. For more information, click here to access an article on "Improving Implants Using Laser-Based Metal Deposition Technologies."

Materials Discovery

It can take decades to develop a new material using conventional methods. Simulation techniques have advanced the state of the art, however material samples still need to be built and analyzed. Traditional manufacturing processes are costly, time-consuming and allow the researcher to evaluate just a single material chemistry at a time. Due to limited research funds, new fabrication techniques must be highly flexible to address a diverse set of research disciplines and industry applications. With LENS systems, material researchers have an ideal tool to address these needs. The LENS MR-7 System allows the materials researcher to rapidly produce novel materials with exceptional quality. Sensors gather the data required to allow processing-property-microstructure relationships to be developed. For more information, click here to access a webinar on "Accelerating R&D of Novel Alloys and Metallic Devices with LENS."

Hybrid Manufacturing

The LENS 3D printer integrates well with conventional processes to create unique hybrid manufacturing solutions. For instance, LENS can be used to enhance an existing component by adding layers of wear-resistant material or other surface treatments. LENS can also produce value-added features on existing parts, such as adding a boss, mounting lug, or flange to a large cast component. For more information, click here to access a Manufacturing Engineering article titled "Building Parts Directly"

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