Electron Beam Melting
Encyclopedia
Electron beam melting is a type of additive manufacturing
for metal parts. It is often classified as a rapid manufacturing method. The technology manufactures parts by melting metal powder layer per layer with an electron beam in a high vacuum. Unlike some metal sintering
techniques, the parts are fully dense, void-free, and extremely strong.
The melted material is from a pure alloy in powder form of the final material to be fabricated (no filler). For that reason the electron beam technology doesn't require additional thermal treatment to obtain the full mechanical properties of the parts. That aspect allows classification of EBM with selective laser melting
(SLM) where competing technologies like SLS
and DMLS
require thermal treatment after fabrication. Comparatively to SLM and DMLS, EBM has a generally superior build rate because of its higher energy density and scanning method.
The EBM process operates at an elevated temperature, typically between 700 and 1.000 °C, producing parts that are virtually free from residual stress, and eliminating the need for heat treatment after the build.
Melt rate: up to 80 cm3/h. Minimum layer thickness: 0.05 millimetre (0.00196850393700787 in). Tolerance capability: +/- 0.2 mm.
This technology was developed by Arcam
AB in Sweden.
alloys are widely used with this technology which makes it a suitable choice for the medical implant market.
CE-certified acetabular cups
are in series production with EBM since 2007 by two European orthopedic implant manufacturers, Adler Ortho and Lima-Lto.
The acetabular cups are manufactured with integrated, engineered trabecular structures for enhanced osseointegration
, and more than 20.000 cups have been implanted to date.
The U.S. implant manufacturer Exactech has also received FDA clearance for an acetabular cup manufactured with the EBM technology.
Aerospace and other highly demanding mechanical applications are also targeted.
The EBM process was recently developed for manufacturing parts in gamma titanium aluminide
, and is currently used by Avio S.p.A. for the production of turbine blades in γ-TiAl for aero engines.
Additive manufacturing
Additive manufacturing is defined by ASTM as the "process of joining materials to make objects from 3D model data, usually layer upon layer, as opposed to subtractive manufacturing methodologies, such as traditional machining...
for metal parts. It is often classified as a rapid manufacturing method. The technology manufactures parts by melting metal powder layer per layer with an electron beam in a high vacuum. Unlike some metal sintering
Sintering
Sintering is a method used to create objects from powders. It is based on atomic diffusion. Diffusion occurs in any material above absolute zero, but it occurs much faster at higher temperatures. In most sintering processes, the powdered material is held in a mold and then heated to a temperature...
techniques, the parts are fully dense, void-free, and extremely strong.
Technology
This solid freeform fabrication method produces fully dense metal parts directly from metal powder with characteristics of the target material. The EBM machine reads data from a 3D CAD model and lays down successive layers of powdered material. These layers are melted together utilizing a computer controlled electron beam. In this way it builds up the parts. The process takes place under vacuum, which makes it suited to manufacture parts in reactive materials with a high affinity for oxygen, e.g. titanium.The melted material is from a pure alloy in powder form of the final material to be fabricated (no filler). For that reason the electron beam technology doesn't require additional thermal treatment to obtain the full mechanical properties of the parts. That aspect allows classification of EBM with selective laser melting
Selective Laser melting
Selective laser melting is an additive manufacturing process that uses 3D CAD data as a digital information source and energy in the form of a high powered laser beam to create three-dimensional metal parts by fusing fine metallic powders together...
(SLM) where competing technologies like SLS
Selective laser sintering
Selective laser sintering is an additive manufacturing technique that uses a high power laser to fuse small particles of plastic, metal , ceramic, or glass powders into a mass that has a desired 3-dimensional shape...
and DMLS
Direct metal laser sintering
Direct metal laser sintering is an additive metal fabrication technology developed by EOS out of Munich, Germany, sometimes also referred to by the terms selective laser sintering or selective laser melting . The process involves use of a 3D CAD model whereby a .stl file is created and sent to...
require thermal treatment after fabrication. Comparatively to SLM and DMLS, EBM has a generally superior build rate because of its higher energy density and scanning method.
The EBM process operates at an elevated temperature, typically between 700 and 1.000 °C, producing parts that are virtually free from residual stress, and eliminating the need for heat treatment after the build.
Melt rate: up to 80 cm3/h. Minimum layer thickness: 0.05 millimetre (0.00196850393700787 in). Tolerance capability: +/- 0.2 mm.
This technology was developed by Arcam
Arcam
For the British high end hi-fi manufacturer please see A&R Cambridge Ltd Arcam manufactures EBM systems, which create parts from metal powders. The process uses standard biocompatible materials, such as Ti6Al4V ELI, Ti Grade 2 and Cobalt-Chrome...
AB in Sweden.
Market
TitaniumTitanium
Titanium is a chemical element with the symbol Ti and atomic number 22. It has a low density and is a strong, lustrous, corrosion-resistant transition metal with a silver color....
alloys are widely used with this technology which makes it a suitable choice for the medical implant market.
CE-certified acetabular cups
Hip replacement
Hip replacement is a surgical procedure in which the hip joint is replaced by a prosthetic implant. Hip replacement surgery can be performed as a total replacement or a hemi replacement. Such joint replacement orthopaedic surgery generally is conducted to relieve arthritis pain or fix severe...
are in series production with EBM since 2007 by two European orthopedic implant manufacturers, Adler Ortho and Lima-Lto.
The acetabular cups are manufactured with integrated, engineered trabecular structures for enhanced osseointegration
Osseointegration
Osseointegration derives from the Greek osteon, bone, and the Latin integrare, to make whole. The term refers to the direct structural and functional connection between living bone and the surface of a load-bearing artificial implant...
, and more than 20.000 cups have been implanted to date.
The U.S. implant manufacturer Exactech has also received FDA clearance for an acetabular cup manufactured with the EBM technology.
Aerospace and other highly demanding mechanical applications are also targeted.
The EBM process was recently developed for manufacturing parts in gamma titanium aluminide
Titanium aluminide
Titanium aluminide, TiAl, is an intermetallic chemical compound. It is lightweight and resistant to oxidation and heat, however it suffers from low ductility. The density of gamma TiAl is about 4.0 g/cm³. It finds use in several applications including automobiles and aircraft...
, and is currently used by Avio S.p.A. for the production of turbine blades in γ-TiAl for aero engines.