Additive Manufacturing Strategies

PowderMegaVaporWorks Working on 65 laser 10m X 10m X 10m Metal 3D Printer

ST Medical Devices

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Joris Peels has revealed that he is working on the PowderMegaVaporWorx MegaDecaDon, a 65 two-kW laser powder bed fusion printer with a powder deposition rate of 130 liters an hour. The powder bed fusion 3D printer will have individual 3D optics on each laser, enabling individual tracking of each melt pool. Real-time data analytics can be analyzed through live heatmapping or tracked over time through simulation and Real Live Reporting. Simultaneous melt pool filtering will ensure optimal melt pool recovery and melt penetration at every single position. An AI array will be used to analyze FLIR data and melt pool physics, as well as powder morphology at every voxel.

Each of the printer’s 65 two-kilowatt lasers will directly report onboard accelerometer data, temperature, telemetry, and force feedback rating to AI GOD, the printer’s sentient central nervous system. AI GOD is powered by a dozen HP Cray ClusterStor E1000 storage units and dual 25 petaflops Cray XC60’s. Each powder grain’s morphology, size, and placement in the powder bed will be tracked in real-time after being individually 3D scanned and placed at the optimal position in the bed to ensure proper flowability. Proprietary MegaTetris algorithms ensure optimal powder orientation and placement. Powder grains with incorrect sphericality or sizing will be rejected by the PWDRSelect powder pick and reject system which uses AI and 3D scanning along with machine learning to identify and select ideal powder.

On board analysis and PrintRPrediKt will simulate every localized variable in a graphical way on one of 23 45-inch touch screens. Laser spot size, power, shape, and color are completely variable and are changed throughout the build depending on geometry. Tru Skywriting is a dynamic system whereby all laser variables are changed depending on the laser speed. Each laser rotates to give optimal coverage while being mounted on its own six DOF axis air bearing unit.

The 10m X 10m X 10m build volume is the largest in the industry and is up to 9135% larger than some other printers in the benchmark. In terms of performance, the PowderMegaVaporWorx 650 is up to 1896% more productive than other 3D printers in the benchmark (the benchmark is a RepRap Mendel). Spanning one football field in length, the PowderMegaVaporWorx 650 is wheelchair accessible and is just the statement piece your national manufacturing laboratory needs.

Are you innovative? Let everyone know by buying a PowderMegaVaporWorx 650. Capable of processing intermetallics, bulk metallic glasses, refractory metals, all nickel-based superalloys (including the elusive Hastelloy XI), stellite, all tool steels, Rhenium, Gallium, Cadmium, and ceramics, this is the can-do printer for you. The only printer in its class with an onboard gas atomization unit, the PowderMegaVaporWorx 650 has the lowest cost per part in the industry.

Powered by a NuScale power module, this low cost per part system has breakthrough economics in additive. An onboard cryogenic air separation system means that your PowderMegaVaperWorx 650 will never run out of argon because you’ll make your own. Industry-leading economics don’t end there; with 16 integrated vertical machining centers, 23 tumblers, a shot peening wall, and jacuzzi-sized drop-in EDM tank you’ll be the envy of your peers. Automated machine vision driven robot conveyancing is standard, as is integrated CT scanning for all parts. Take a load off in the integrated de-stressing lounge while you enjoy the whir of your 10-axis CNC finishing off parts. Currently, at the idle sketch phase, the PowderMegaVaperWorx 650 will probably be rectangular and is scheduled to be launched in Q5 2021.

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