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The

Fusion Factory

The

Fusion Factory

The FUSION FACTORY is an integrated Additve Manufacturing (AM) based solution for the manufacturing of complex metal and ceramic parts. It integrates the machines for all necessary technological steps in one system. The result is a complete process chain in one frame. The combined machines fulfil all requirements for an industrial level production and quality control.

The base of the development is XERION´s experience for more than 20 years design and production of furnaces for research and industry and the confidence of our customers in four continents. The idea of modules extend the possibilities of the system. Modules can be substituted or added. Taking inspiration from Metal Injection Moulding (MIM) and the already vast experience gathered over the years in the field, the Fusion Factory aims to further ameliorate the MIM technique through the application of the ever-evolving AM technology to produce parts which are technologically or economically (or both) not feasible with the current state-of-the-art. 

 

The ability of the system to print with multiple materials further adds to the manufacturing flexibility and makes the creation of composites with complex geometries possible.

Such a technology not only extends the capability of desktop printers beyond prototyping but also offers an accelerated and agile solution for the spare parts industry, where downtime of machinery is a critical issue and delivery of parts overseas could sometimes take weeks.

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Step 1

Print it!

The specially fabricated filaments, which are a mixture of organic compounds and metal / ceramic powder, is fed to a modified Fused Filament Fabrication based printer through which the green part, as it is technically christened, is printed.

This process is no different from the one that is used to produce plastic models, with the exception of the special filaments and the specially designed printer nozzle and feed mechanism.

The feed mechanism is 100% made from steel, so the stability and lifetime is very high.

 

Step 2

Treat it!

The process of binder elimination begins with submerging the green part inside the chemical bath of the FUSION FACTORY’s very own customized Debinding station.

The solvent reacts with the materials on the surface, creating microchannels that further allow it to diffuse deeper into the solid matrix, eliminating the organic compound from deep within. Most of the binder is eliminated this way and the microscopic channels created further act as an outlet for the thermal vaporisation of the remaining organic chemicals in the next step.

The process is highly automated, the operator will not come in contact with the solvent or with solvent vapour and all standards are strictly observed. The Debinding process lasts for several hours and we are just one step away from the part being ready.

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Step 3

Compact it!

With the elimination of the organic component, the new matrix of the material is now porous with empty spaces evacuated by the binding agent via debinding. Such a part is merely metal powder held loosely together and would break if not handled gently. And that is why we need to compact or sinter it!


In such a process, the material is heated to very high temperatures (>1.000°C) causing the outer shell of the metal powders to melt and fusing them together (a bit like welding). This now makes the material compact and dense, and results in slight shrinkage, which can be precompensated in software prior to carrying out the process.


The sintering process is done under a protective atmosphere, for stainless steel, mostly under 100% hydrogen. This is the longest process in the manufacturing chain of the FUSION FACTORY and takes usually more than 10 hours.

Control

Unit

The Control Unit is the centralized processor of the FUSION FACTORY, carefully co-ordinating and synchronizing every step in the process chain with utmost precision, while complying to the necessary industrial standards.

The Control Unit has built in fail-safe features ensuring redundancy and is complemented with a touch screen for the user-friendly experience of the operator. The database management system on-board enables the storage of pre-programmed “recipes”, automising laborious task of working with multiple machinery, and in the process ensuring excellent quality and repeatability of the manufactured parts.

In addition to this, the Graphical User Interface enables a complete supervision and control of all processes and even permits multi-tasking through network-assisted communication between the FUSION FACTORY and your desktop.

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The

Advantages

... of filament based 3D-Printing of metals and ceramics:

•  Highest percentage of powder utilization of all AM techniques

•  Cost effective solution as compared to other contemporary AM methods

 

•  Relatively short printing times  

•  Cavities and infill profiles (with controllable infill percentage) can be manufactured 

 

•  Easy way of producing multi material components

•  High Technology Readiness Level (TRL) of printing process

... of the Fusion Factory

•  Automated process chain from filament to ready-to-use component

•  Concept applicable for metals and ceramics

•  Production of all sorts of complex geometries within appr. 2 working days

•  Lower cost of production as compared to contemporary AM systems

•  Minimum technician intervention from the point of upload of computer file to the part being manufactured

•  Open system permitting use of filaments from other suppliers

•  High precision of manufactured parts with little or no need of further machining to improve product quality.

•  Robust and industry-friendly design of the machine

•  Control with fail-safe industrial Siemens S7-1500 Controller

•  User-friendly recipe creation for all technology steps

•  Remote access to system eliminating need for on-floor supervision

 

•  Automatic report generation with all relevant parameters including Operator names based on a professional data management system

•  Machinery compliance with all relevant national and international standards

•  Compact design suitable for all workshops and laboratories

•  Robust frame with crane eyes for easy transport of the system

•  System completely designed and manufactured in Berlin / Germany, therefore a deep understanding of the technology and it’s state-of-art

•  As an option, execution in accordance with the standard „AMS2750E“ possible

•  Minimum technician intervention from the point of upload of computer file to the part being manufactured

•  Open system permitting use of filaments from other suppliers

•  High precision of manufactured parts with little or no need of further machining to improve product quality.

•  Robust and industry-friendly design of the machine 

 

•  Control with fail-safe industrial Siemens S7-1500 Controller

•  User-friendly recipe creation for all technology steps

•  Automatic report generation with all relevant parameters including Operator names based on a professional data management system

•  Remote access to system eliminating need for on-floor supervision

•  Machinery compliance with all relevant national and international standards

•  Compact design suitable for all workshops and laboratories

•  Robust frame with crane eyes for easy transport of the system

•  System completely designed and manufactured in Berlin / Germany, therefore a deep understanding of the technology and it’s state-of-art

•  As an option, execution in accordance with the standard „AMS2750E“ possible

 

 

 

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Fusion Factory is a product brand of
XERION BERLIN LABORATORIES ® GmbH
Salzufer 15/16, D-10587 Berlin

Contact Us:
Tel. +49 (0) 30 - 20 09 70 20

E-Mail: fusionfactory@xerion.de