their traditional limitations.
In addition, the process enables metallurgical
requirements to be tailored to application requirements,
rather than the previous limitations of the process, which
it claims produces “optimum results”.
“It has long been recognised that electron beam-based
power bed processes offer signi cant advantages over
laser-based processes, as the energy transfer physics are
more favourable for an electron beam than laser, enabling
users to create stress-free parts with excellent
metallurgy,” says Hansford.
metals. Aluminium and tool steels are yet to be tested.
The machine will be suitable for a range of applications
across different industrial sectors, including aerospace,
space, defence, motorsport, nuclear, medical imaging,
turbo machinery, heat sicks, tooling, cutting, and mining.
Calibur3 and the NeuBeam technology have a range of
bene ts over other AM processes, according to Hansford.
These include higher productivity, large build volumes,
thermal management, rapid material development,
microstructure management, good surface nish, ne
powder capability, high powder recycling rates, easy part
recovery and nishing, large hot parts without stresses
LEAD FEATURE GROUND-BREAKING METAL AM TECH
and ultimately support free parts.
“NeuBeam technology lends itself to rapid application
and material development, as users can monitor the full
the market next month
process, effect the cooling cycle, changing the
microstructure to suit their needs,” says Hansford.
Wayland Additive says Calibur3 will provide increased
exibility – giving users more complete open control in
designing parts and materials due to a more tolerant and
transparent process, control over material properties,
freedom and tools for multi-materials, fully open
parameters with no black box, design freedom, variable
supports/sinter cake, parts are fully designed for
production and a simpli ed post-processing.
This “complete stability” has aimed to eliminate
process instability from electron beam-based AM to create
a technology that will transfer directly from the lab to the
production line. The NeuBeam process means there are
no smokes, is a large stable operating window, more
stability than eBeam or laser, no gas ow limitations on
part size, advanced in-process monitoring and control, part
traceability and quali cation, no stress or distortion and
easy machine calibration.
Better metallurgy is also achieved, as fully dense parts
are created for users with tailored metallurgy, without the
need to stress relieve parts post-process.
The process also ensures optimised energy output
through power transfer from the beam to the powder
bed, creating fully dense parts for a wide range of
materials and layer thicknesses. Parameter control is
also better, as users have complete control over melt
parameters, enabling microstructures to be tuned and
optimised for the applications. Users will also get
powder integrity – as there is no need to sinter the
powder, as the surrounding powder is not exposed to
The existing electron beam process is limited by
charge transfer instabilities, which are constantly
balanced on a knife-edge and one wrong move can easily
lead to catastrophic build failure for manufacturers.
The team at Wayland believes there is “fundamental
aw” with existing eBeam systems, and the biggest
technical challenge is powder charging - the main cause of
build failure that limits the amount of parameter variations
available to end users. In this process, the beam transmits
charge to the power before the particles become charged
and then the charged particles semi-sintered together to
prevent a repelling ‘smoke event’.
Through the NeuBeam process, Hansford says it has
solved the aw with existing eBeam systems by freeing up
the process, as users are no longer constrained and
allowing for further expansion on parameters. This it says
has created an ideal environment for material development
and production. The beam no longer transfers charge to
the powder, so the powder remains free around the parts,
added in insulating the build.
RAFT OF CAPABILITIES
Calibur3 will have a build volume of 300x300x450mm, but
an ugraded Calibur4 will arrive later in 2021 with a build of
450x450x450mm. It will also come with a material
development kit build volume of 100x100x150mm.
Calibur3 has been built so that when any upgrades are
developed, such as when the bigger build Calibur4 is
launched, or software improvements are made,
manufacturers can get them added to the machine.
Hansford notes the larger build area is something
customers have asked for, while plans are also in the
pipeline to develop a multi-point melt strategy, something
not currently possible with current laser AM technology.
A range of materials can be used on Calibur3, including
Ti64, Ti aluminide, tungsten, nickel based super alloys,
copper, CM247, vibenite range/carbide allots, refractory
www.machinery.co.uk | MachineryMagazine | @MachineryTweets | February 2021 11