Additive Manufacturing

Additive manufacturing is an innovative technological process capable of producing articles by aggregation of material starting from a three dimensional digitized reference model, usually by overlapping layers, in opposition to the more conventional subtractive manufacturing technologies, in which an object is created by cutting away solid blocks of material until the final product is complete. Seamthesis offers an integrated service (one-stop-shop) to its customers and engineering: from commercial and technical consultancy, to support for the definition of the machine to be purchased; from support for the initial set-up of the process and the production of the first products, to advanced training for operators and technicians, both in the classroom and on-site. Additive manufacturing has already reached the due industrial maturity to make finished components for industrial equipment, cars, planes, energy systems and structural parts of the human body.

Skills and competencies

Definition of the characteristics of the systems according to the customer's needs (e.g. PBF titanium printing with EOS M290)

Advanced training on the safe use of systems and execution process

Design and development of metal powders and components, produced for MA (different technologies and energy sources)

Desining and printing in PEEK, Ultem, PVA, PLA, ABS, Carbon Fiber, Wood, Nylon, PC, PTEG, HIPS, PP, Flexible, TPU, ecc...

Main activities (metal and plastic based)

  • 1. selecting the best metal powders for the process and the component, metallurgical design of new powders (patentable as well) for MA on specific custmer request.
  • 2. 3D metal printing with PBF technology (laser ed EBM-Electron Beam Melting) and DED laser (Direct Energy Deposition)
  • 3. data preparation, designing printing startegy and printing parameters.
  • 4. disegno CAD di parti e assemblati
  • 5. parts and mechanical build-up components for MA (DfAM) re-engineering, using the main commercial SW
  • 6. ottimizzazione topologica di parti e di assemblati, anche multibody; ottimizzazione volume di stampa
  • 7. analisi strutturale tramite codici FEM per la validazione di parti e strutture, anche con accoppiamento termomeccanico e microstrutturale
  • 8. calcolo termo-fluidodinamico (CFD) e ottimizzazione dei canali tramite morphing per MA
  • 9. simulazione termomeccanica ai volumi finiti del processo di stampa additiva (anche a supporto della determinazione dei parametri di stampa di nuove polveri metalliche)
  • 10. conversione in modello 3D (.STL) di immagini diagnostiche (es. DICOM, x-ray, JPEG, TIFF, BMP, raw image data), manipolazione della superficie tassellata (con particolare riferimento alle applicazioni biomedicali (es. protesi ossee)
  • 11. progettazione degli esperimenti (DOE)
  • 12. post-processing e finitura dei manufatti stampati 3D (es. per metallo: trattamenti termici di qualità, finitura meccanica superficiale, rimozione dei supporti, sabbiatura/pallinatura, pulizia elettro-chimica e tramite US, anodizzazione). Su richiesta è possibile provvedere a realizzare l'intero ciclo di qualifica e certificazione del componente, secondo specifiche Cliente o standard internazionali (normative).

Some examples of 3D metal printing activities and products

Intermediate production operations for metal items with PBF laser technology

Development/optimization of process parameters, functional characterization of metal powders.

MA redisign (weight reduction, topological optimization, print volume optimization)

Silicone molds

Dime di controllo e nasi di piega alleggeriti a nido d'ape

filters for Oil&Gas e Automotive field, CFD optimized

Results impossible to get using subtractive manufacturing

Anodizing of printed components in Ti64 ELI aestethic purposes (processo proprietario)

Designing and printingdental prothesis biomedical Ti alloy

Ventosa per manipolazione sottovuoto con microcanali curvi incorporati

fashion accessories

Office professional accessories

Provini per test di trazione (qualifica del materiale)

Cassa per compressore industriale in AlSi7Mg0.6

Blades for wind turbines in Ti6Al4V

Camere di combustione ossigeno/idrogeno per CubeSAT con ugello de Laval in Ti6Al4V

(courtesy: MIPRONS Srl)

Keyholder Seamthesis

Ruota dentata alleggerita con struttura lattice

Girante di compressore

Bob (Minion)

Provini per test DMA (dynamic mechanical analysis)

decorative element

Mockup AIAS medals 2019

Vessel

Scale-up camere di combustione per applicazioni aerospaziali

(courtesy: MIPRONS Srl)

Elettrolizzatore per applicazioni aerospaziali

(courtesy: MIPRONS Srl)