Sciaky Inc., a subsidiary of Phillips Service Industries, provides additive manufacturing solutions for large-scale, high-value metal parts. As of September 1, 2014, the company will be offering its electron beam additive manufacturing (EBAM) systems for purchase.
Previously, the company has only offered its additive manufacturing process as a service-only option to manufacturers who needed help in producing large-scale prototypes and production parts made out of high-value metals like titanium, tantalum, stainless steel and Inconel. The technology has been in projects for the U.S. Air Force, Lockheed Martin, DARPA and Boeing.
The EBAM process, which has been marketed as Direct Manufacturing (DM), combines computer-aided design (CAD), electron beam welding technology and layer-additive processing. Starting with a 3D model from a CAD program, Sciaky’s fully articulated, moving electron beam welding gun deposits metal (via wire feedstock), layer-by-layer, until the part reaches near-net shape. From there, the near-net shape part requires minor post-production machining.
Deposition rates of Sciaky’s EBAM process range from 7 lb/hr to 20 lbs/hr, depending upon part geometry and the material selected. The build envelope can reach up to 19ft x 4ft x 4ft (L x W x H), allowing manufacturers to produce very large parts and structures, with virtually no waste. As a result, manufacturers can drastically reduce material costs, lead times, and machining time, when compared to traditional manufacturing methods.