A groundbreaking development at ETH Zurich has revolutionized the world of 3D printing with the creation of a cutting-edge laser powder bed fusion machine. This innovative machine utilizes a circular tool path to print round components, enabling the processing of multiple metals simultaneously. The implications of this advancement are far-reaching, with significant reductions in manufacturing time and exciting new possibilities for the aerospace and industrial sectors.
The newly developed 3D printer allows for the fusion of two different materials using a laser on a rotating platform. This breakthrough technology has been met with great enthusiasm and interest, prompting ETH to file a patent application for the machine. The remarkable results of this project have been published in the prestigious CIRP Annals, solidifying its place in the realm of advanced manufacturing.
In today’s world, the use of 3D printing in the production of modern rocket engines has become indispensable for optimizing performance. The introduction of a high-speed multi-material metal printer at ETH Zurich represents a significant leap forward in this field. By rotating the powder deposition and gas flow nozzles during the printing process, this machine can handle multiple metals simultaneously, eliminating process dead time and streamlining production.
The development of this groundbreaking machine was spearheaded by a team of six Bachelor’s students at ETH Zurich, working under the guidance of Professor Markus Bambach and Senior Scientist Michael Tucker. The project, known as Focus Project RAPTURE, was completed in a remarkably short span of nine months. The machine’s primary focus is on aerospace applications, particularly cylindrical geometries like rocket nozzles and turbomachinery, but its potential extends to a wide range of mechanical engineering applications.
One of the driving forces behind this project was the goal of developing bi-liquid-fueled rocket nozzles for ARIS, the Swiss Academic Space Initiative. With aspirations of launching rockets into space and reaching the Kármán Line, ARIS required a solution that could withstand extreme heat and pressure. The multi-material capabilities of the new 3D printer make it an ideal candidate for creating rocket nozzles with complex geometries, such as heat-conducting copper interiors with integrated cooling channels and heat-resistant nickel alloy exteriors.
Overall, the development of this groundbreaking laser powder bed fusion machine at ETH Zurich represents a significant advancement in the field of 3D printing. By enabling the simultaneous processing of multiple metals, this technology has the potential to revolutionize manufacturing processes across a wide range of industries, paving the way for new innovations and possibilities in aerospace and beyond. “For smaller players like our student rocket team, the realm of multi-material technology has always seemed out of reach due to its complexity and cost,” explains Tucker, a member of the team. However, their latest innovation, the RAPTURE machine, is changing the game.
At the core of this new machine is a rotating platform that revolutionizes the printing process. Unlike traditional 3D printers that require the application of a new layer of powder after each melting phase, the RAPTURE machine operates continuously. This simultaneous application and fusion of powder by the laser significantly boosts productivity, reducing manufacturing time for cylindrical components by over two thirds.
“This innovative process is perfect for creating components like rocket nozzles and rotating engines in the aerospace industry,” Tucker notes. The machine excels in producing large-diameter components with thin walls, making it ideal for intricate geometries. The rotating method is particularly effective for crafting non-axisymmetric parts or arrays of components.
Moreover, the RAPTURE machine can handle two different metals simultaneously in a single operation, streamlining the manufacturing process. Traditional systems require multiple steps and a larger quantity of metal powder, leading to wastage during separation and recovery. In contrast, the RAPTURE machine deposits material only where needed within the component, minimizing waste.
To ensure high product quality, the machine incorporates a gas flow mechanism that shields the component from oxidation during printing. By efficiently extracting by-products like soot and spatter, the machine maintains a clean working environment. Tucker emphasizes the importance of this gas flow mechanism in optimizing product quality, which is made possible by the machine’s rotating architecture.
Building the RAPTURE machine presented various technical hurdles for the student team, such as synchronizing the scanning laser with the rotating gas inlet and powder supply. Additionally, many of the required parts were not commercially available, prompting the team to design custom components like a rotatable gas inlet connection and an automated powder refill system.
Despite these challenges, the student team has created a machine that is on the cusp of industrial readiness. With the RAPTURE machine, the once-unattainable realm of multi-material 3D printing is now within reach for small players like their rocket team, opening up a world of possibilities for innovation and customization in manufacturing.”
