UNPRECEDENTED MATERIAL CAPABILITIES
Nickel, Cobalt-based alloys
Iron, Titanium-based alloys
FormAlloy’s award-winning directed energy deposition (DED) systems enable customers to FORM, ENHANCE, and REPAIR metallic parts that go beyond the bounds of traditional manufacturing. FormAlloy's 3D metal printing technology utilizes DED to create metallic parts to near-net shape, while increasing the design envelope and providing a more economical solution than producing the same part with conventional methods.
With FormAlloy’s technology, customer and clients will be able to confidently FORM parts 2-100x faster than other methods and produce high quality, repeatable builds with in-process monitoring and control features. The X&L-Series systems enable reduced machining time and nearly eliminate material waste, particularly with high-value materials such as titanium and Inconels. Additively Manufactured parts from FormAlloy can provide design features that can’t be achieved with conventional manufacturing methods, such as internal cooling channels and multi-metal parts.
Unlike powder-bed technologies such as direct metal laser sintering (DMLS), FormAlloy’s DED process deposits metal with a coaxially aligned laser/powder nozzle. With the FormAlloy process, clients and customers achieve faster build times, superior material capabilities, and larger build envelopes compared with powder-bed technologies.
FormAlloy’s DED process can produce parts with dimensions from less than 1 mm to greater than 1 meter with bead widths from 250 micron and up.
FORMALLY'S 3D PRINTING TECHNOLOGY
NASA ROCKET NOZZLE PART - INCONEL 625
ADDITIVE MANUFACTURED EXAMPLE
AS-PRINTED RESOLUTION - INCONEL 625
FormAlloy’s technologies can ENHANCE existing products by laser cladding for superior performance, adding dimensional features, and depositing bi-metallic and multi-gradient material.
FormAlloy's Cladding technology is used to create wear and corrosion-resistant coatings that are 100% dense and metallurgically bonded to the substrate. The cladding process inputs minimal heat to the part compared with PTA, TIG and MIG weld processes. LMD provides very low dilution between the coating and substrate and allows for fine deposit microstructures, precise control of the coating thickness and reduced distortion into the base part. For wear resistance, a variety of nickel, cobalt, and carbide-based powders can be used.
With the capability to add features and materials, FormAlloy systems provide the ability to improve legacy and new products with geometric and alternative material additions. The additional features can provide a wide range of benefits from improved mechanical properties to higher temperature capabilities.
FORMALLOY'S LASER CLADDING TECHNOLOGY
IN718 / IN625 / STELLITE 6 (LEFT)
IN625 / COPPER (RIGHT)
Formalloy’s REPAIR technology can be used to rebuild damaged or worn areas of valuable machine components, dies or molds. LMD produces 100% dense, metallurgically bonded features to the damaged part, with layer thickness from microns and up, thus enabling a variety of repair applications that require minimal post-process machining.