Customer demonstrator of large-scale metal 3D printing

Important results from the project

The goal of the project has been to validate Procada´s newly developed control system for large-scale 3D printers (intended for critical metal components found in e.g. aerospace) by building a large complex structure automatically. The aim is to demonstrate the potential of Procada´s unique automation solution that enables new applications for 3D printing where efficiency and material integrity are two important factors. A complex demonstrator will allow Procada to build trust with both customers and investors, and thereby accelerate the commercialization of the technology.

Expected long term effects

During the project, a completely new laser-wire deposition tool was designed with the aim to endure long-durational builds. With the tool and Procada´s control system a complex demonstrator corresponding to an aircraft engine mount was built in record time and with little process tuning. The controller allows for steep angle wire feeding and omnidirectional deposition motion which is highly advantageous and in fact needed for a complex structure to be printed efficiently. The new tool and the controller performed perfectly and the demo has already gained significant attention.

Approach and implementation

A laser tool has been modified to endure high radiant heat present in large-scale 3D printing. The tool, which is installed in a robot cell, was upgraded with Procada´s new control system. Based on a CAD drawing of the demonstrator, the robot´s paths were programmed. Using the control system, efficient process parameters could be produced in a short time and the demonstrator could then be built. Four different control systems were active throughout the printing sequence and the results show that it is possible to build large-scale complex structures completely automatically.