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Hydraulic Expansion Toolholders With Cool Flow For Optimised Machining

Hydraulic Expansion Toolholders With Cool Flow For Optimised Machining

SCHUNK breaks down the development of its Cool Flow technology—a highly efficient cooling system which feeds coolant directly through the tool mounting, with the help of a model, tool and mould-making company from Germany. 

At the model, tool and mold-making company KRIEGER, standardisation is a key success factor. Within a decade, the variety of machine control systems, tool mountings and tools that had been developed were systematically analysed, structured and overhauled. 

Today, all machines come with standardised control systems, a uniform interface and specific tool pools. Even for special and customised tools, an in-house tool catalog has been drawn up in order to cut down on uncontrolled growth. This creates clarity and makes it easier to detect and eliminate even the smallest of deviations in processes. 

This includes deviations such as vibrations that can occur, in particular on machines with large traverse paths (2500 mm x 2000 mm x 1000 mm). Although the vibrations had been kept in check by changing the cutting parameters, there had long since been dissatisfaction with the overall process. 

Technological Progress with Hydraulic Expansion Toolholders

KRIEGER first deployed the TENDO Slim 4ax vibration-damping hydraulic expansion toolholders in a milling test to replace the previous standard heat shrinking mounting which was susceptible to vibrations. They found that the machines absorb the vibrations considerably better and no longer come to a standstill during demanding processes if they are equipped with the toolholders. 

Particularly on machining centers that lack stability due to their design and size, the effect has been enormous. The toolholders could simply be replaced without any reprogramming or collision check. 

It made sense for the 40-person company to deviate from what was hitherto tried-and-tested and the company was convinced.

Simple Replacement Via Plug & Work

Test series have proven that mounting with the vibration-damping characteristics of hydraulic expansion toolholder technology results in significant process improvements, especially during drilling, as well as demanding finish milling. Users benefit from shining surfaces, long tool service live, and efficient metal cutting. 

Unlike heat shrinking toolholders, the TENDO Slim 4ax can be seamlessly integrated into SCHUNK’s tried-and-tested hydraulic expansion program, with a constant run-out accuracy of < 0.003 mm at an unclamped length of 2.5 x D and a balancing grade of G 2.5 at 25,000 RPM. 

Since precision mountings can replace conventional heat shrinking toolholders by means of Plug & Work without having to reprogram the outside contour, its advantages can be immediately tested in real applications and used in the long term – just like at KRIEGER.

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Injection Moulding Machine Market Worth $12.3 Billion By 2025

Injection Moulding Machine Market Worth $12.3 billion By 2025

According to the new market research report by MarketsandMarkets, the Injection Moulding Machine Market is projected to reach USD 12.3 billion by 2025, at a CAGR of 3.6 percent from USD 10.3 billion in 2020.

An injection moulding machine is used for manufacturing products made up of plastics, rubber, metal, and ceramic. It consists of two main parts – an injection unit and a clamping unit. The injection unit is like an extruder, whereas the clamping unit is concerned with the operation of the mould. Injection moulding machines can fasten the moulds either at the horizontal or the vertical position. There are three types of injection moulding machines – hydraulic injection moulding machines, all-electric injection moulding machines, and hybrid injection moulding machines.

Hydraulic injection moulding machine is the largest type segment of the injection moulding machine market. APAC was the largest market for synthetic leather in 2019, in terms of both volume and value. Factors such as growing demand from healthcare industry, rapid industrialisation in growing economies like China, India & Thailand and increasing demand for plastic moulds in electric vehicles will drive the injection moulding machine market.

Healthcare is projected to be the fastest growing end-use industry in the market between 2020 and 2025

Injection moulding machines are preferred for manufacturing medical products, as these machines offer high precision, accurate, and complex injection moulded parts. These machines have application in surgical and medical devices such as syringes, vials, medical instruments, inhalers, cannulated, medicinal connectors, air systems, and prescription bottles. The outbreak of coronavirus across the globe has highlighted the healthcare industry. Due to explosive surge in the number of Covid-19 cases, the demand for medical equipment like syringes, air systems, and other medical instruments increased exponentially. Countries such as India and China became the hub for manufacturing and meeting the demand for all these equipment across the globe.

APAC is projected to be fastest growing region for the market during the forecast period

The APAC comprises major emerging nations such as China and India. Hence, the scope for the development of most industries is high in this region. The injection moulding machine market is growing significantly and offers opportunities for various manufacturers. The APAC region constitutes approximately 61.0 percent of the world’s population, and the manufacturing and processing sectors are growing rapidly in the region. The APAC is the largest injection moulding machine market with China being the major market which is expected to grow significantly. The rising disposable incomes and rising standards of living in emerging economies in the APAC are the major drivers for this market.


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Driving Hard On The Race Track: Wear-Resistant Iglidur Gears In The Gearbox

Driving Hard On The Race Track: Wear-Resistant iglidur Gears In The Gearbox

The iglidur I6 gears from the 3D printer for car racing of the “Youth Discovers Technology” (Jugend entdeckt Technik – JET) challenge

Electromobility is a crucial topic of the future. For Germany to be in the pole position, it is important to inspire young minds to take up scientific and engineering professions. Towards this purpose, the annual JET Challenge takes place at the IdeenExpo in Hanover. Students are given the task of building a fast, tough and energy-efficient racing car from a standard, remote-controlled car with a limited budget. Wear-resistant 3D-printed gears from igus made from the high-performance plastic iglidur I6 helped in this endeavour.

Build a fast, energy-saving racing car from an ordinary, remote-controlled car and overtake all other teams in a race – that’s the goal of the “Youth Discovers Technology” (Jugend entdeckt Technik – JET) Challenge, organised by the Society of German Engineers (Verein Deutscher Ingenieure – VDI) and the University of Hanover (Hochschule Hannover – HSH). As with the renowned models, the key factor is not speed alone, but also energy efficiency. In June 2019, visitors to the IdeenExpo can see the JET Challenge in action at the HSH trade fair stand. 25 teams compete for victory with their racing cars on a 1:10 scale on a 20-metre race track. The rules are strict. Available to each team is a budget of just 50 euros. Apart from battery, motor and speed controller, all components must be purchased, developed or built by yourself.

Save money with the igus 3D printing service

The teams are currently preparing for the next IdeenExpo. Students of the Eugen Reintjes vocational school are relying on a wear-resistant and tough gear transmission to enhance the performance of their race car. The biggest difficulty with this gearbox was the gear procurement. Due to the small budget, the students couldn’t afford big innovations. Finally, they found what they were looking for at the motion plastics specialist igus in Cologne: cost-effective, low-wear gears from the SLS printer. After a simple online configuration, the gears were printed and provided, made from the high-performance plastic iglidur I6.

High performance plastic makes race cars tough

Laboratory tests prove that the material I6 is significantly tougher than other plastics. In an experiment at our in-house test laboratory, the engineers tested gears made of polyoxymethylene (POM) and iglidur I6 at 12 revolutions per minute and loaded with 5Nm. A machined gear made of POM failed after 621,000 revolutions, while iglidur I6 was still in very good condition after one million revolutions. Thus, the team does not have to worry about potential failures. The gears in the racing car have already successfully completed an initial test run. The car is energy efficient and still reaches the top speed of 60km/h.

The young engineers support from igus promotes innovative projects

Innovative projects such as the race car gears for the JET Challenge are supported by igus as part of the young engineers support. The initiative supports young pupils, students and inventors in the development and execution of their technical projects.


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TRUMPF Commits To E-Mobility And Sustainable Battery Production

TRUMPF Commits To E-Mobility And Sustainable Battery Production

The TRUMPF Group’s corporate venture capital unit has acquired a minority stake in the US start-up Battery Resourcers. Headquartered in Worcester, Massachusetts, Battery Resourcers has developed an efficient and eco-friendly process for recycling lithium-ion batteries. Unlike conventional methods that start by breaking down batteries into their separate chemical components, this new approach directly synthesizes new battery-ready cathode active materials from spent lithium-ion cells.

“The new recycling process developed by Battery Resourcers enhances the sustainability of e-mobility. It keeps scarce resources available in the circular economy, cuts the cost of manufacturing new battery cells, and saves energy in the production process,” says Dieter Kraft, Managing Director of TRUMPF Venture. The new technology recovers 97 percent of the metals contained in the battery cell, reducing cathode cost by 35 percent which compares well to manufacturing a new cell from virgin material. It also reduces production emissions by around 32 percent and energy consumption by 13 percent.

Lithium-ion batteries lie at the heart of most of today’s commercial electric vehicles. They are made from materials such as lithium, nickel, manganese and cobalt, which are expensive to mine and, in some cases, unsustainable. This is why the industry is determined to find the most efficient way to recycle battery cells.

“Our aim is to establish a sustainable value chain for lithium-ion batteries. Our technology can recycle almost all the materials used in cell production – not just for the batteries used in e-mobility, but also for the kinds of smaller batteries found in consumer electronics as well as large, industrial storage batteries regardless of their Lithium-Ion-based chemistries,” says Mike O’Kronley, CEO Battery Resourcers. Conventional recycling options are based on complex processes that mechanically crush the battery cells and chemically separate the mix of materials into individual purified constituent elements such as nickel, cobalt, manganese and lithium. The new method developed by Battery Resourcers eliminates much of this chemical processing by allowing the material mix to be turned into new active cathode material without the separation step, still resetting all memory from previous applications.

“This is a field that will be vitally important in the future. By investing in Battery Resourcers’ promising technology, we’re reinforcing our commitment to e-mobility,” says Kraft. As a key provider of high-tech manufacturing equipment, TRUMPF already plays an important role in driving forward e-mobility. The company’s systems and machines are ideally designed for tasks such as cutting sheet-metal components for battery housings and foils, and TRUMPF lasers are the perfect choice for welding battery cells, electronic contacts and electric motors.


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BMW And Ford Lead $130 Million Investment In Start-Up For Solid-State Batteries

BMW And Ford Lead $130 million Investment In Start-Up For Solid-State Batteries

Solid Power, an industry-leading producer of all solid-state batteries for electric vehicles has announced a $130 million Series B investment round led by the BMW Group, Ford Motor Company and Volta Energy Technologies. Ford and the BMW Group have also expanded existing joint development agreements with Solid Power to secure all solid-state batteries for future electric vehicles.

The investment positions Solid Power to produce full-scale automotive batteries, increase associated material output and expand in-house production capabilities for future vehicle integration. The BMW Group and Ford aim to utilise Solid Power’s low-cost, high-energy all solid-state battery technology in forthcoming electric vehicles.

“BMW and Ford now share leading positions in the race for all solid-state battery-powered electric vehicles,” said Doug Campbell, CEO and co-founder of Solid Power. “Solid Power now plans to begin producing automotive-scale batteries on the company’s pilot production line in early 2022 as a result of our partners’ continued commitment to Solid Power’s commercialisation efforts.”

Solid Power has demonstrated its ability to produce and scale next-generation all solid-state batteries that are designed to power longer range, lower cost and safer electric vehicles using existing lithium-ion battery manufacturing infrastructure.

Solid Power’s leadership in all solid-state battery development and manufacturing has been confirmed with the delivery of hundreds of production line-produced battery cells that were validated by Ford and the BMW Group late last year, formalising Solid Power’s commercialisation plans with its two long-standing automotive partners.

“Solid-state battery technology is important to the future of electric vehicles, and that’s why we’re investing directly,” said Ted Miller, Ford’s manager of Electrification Subsystems and Power Supply Research. “By simplifying the design of solid-state versus lithium-ion batteries, we’ll be able to increase vehicle range, improve interior space and cargo volume, deliver lower costs and better value for customers and more efficiently integrate this kind of solid-state battery cell technology into existing lithium-ion cell production processes.”

“Being a leader in advanced battery technology is of the utmost importance for BMW. The development of all solid-state batteries is one of the most promising and important steps towards more efficient, sustainable, and safer electric vehicles. We now have taken our next step on this path with Solid Power,” said Frank Weber, Member of the Board of Management BMW AG, Development.

Solid Power is currently producing 20 ampere hour (Ah) multi-layer all solid-state batteries on the company’s continuous roll-to-roll production line, which exclusively utilises industry standard lithium-ion production processes and equipment.

Both Ford and the BMW Group will receive full-scale 100 Ah cells for automotive qualification testing and vehicle integration beginning in 2022. Solid Power’s all solid-state platform technology allows for the production of unique cell designs expected to meet performance requirements for each automotive partner. Solid Power’s truly all-solid cell designs achieve higher energy densities, are safer and are expected to cost less than today’s best-performing lithium-ion battery cells.


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Evonik’s Research Hub In Singapore Launches New Line Of Photopolymers For 3D Printing

Evonik’s Research Hub In Singapore Launches New Line Of Photopolymers For 3D Printing

Evonik has developed two photopolymers for industrial 3D printing applications and introduces them under the brand names INFINAM TI 3100 L and INFINAM ST 6100 L. The two ready-to-use materials were conceptualised and invented in Evonik’s research hub in Singapore. They mark the start of a new product line of polymer resins suitable for use in common VAT polymerisation technologies such as SLA or DLP.

“With the new product line, we are entering the market-relevant photopolymer technology stream, strengthening our long-term market position as materials experts for all major polymer-based 3D printing technologies,” says Dr. Dominic Störkle, head of the Additive Manufacturing Innovation Growth Field at Evonik. “With the new ready-to-use formulations, we are also continuing our materials campaign and driving industrial-scale 3D printing as manufacturing technology along the entire value chain.”

Starting signal for a new photopolymer product line

The first high-performance material from Evonik’s photopolymer product family leads to high toughness and impact-resistant 3D parts. The combination of properties makes INFINAM TI 3100 L the new standard for additive manufacturing of industrial components using VAT polymerisation technologies such as SLA and DLP. The impact resistance measured on printed components is 30 J/m3 with a high elongation at break of 120 percent. The new material can therefore withstand strong impact or permanent mechanical effects such as pressing or impact. The range of possible applications extends from industrial to automotive parts and individual applications in the consumer goods sector, which, in addition to design-free forms, require strong mechanical loads in object use.

The second formulation is setting-up a new benchmark in high strength photo-resin category with a combined tensile strength of 89 MPa, flexural stress of 145 MPa and HDT of 120 deg C, which fills the material gap in ultra-high strength photopolymers. These special material properties make INFINAM ST 6100 L the material of choice for applications which need high temperature resistance combined with high mechanical strength.


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New Opportunities For Aerospace With DED 3D Printing Technology

New Opportunities For Aerospace With DED 3D Printing Technology

5-axis DED 3D printing is opening new possibilities and finding its own niche in the manufacturing industries. ModuleWorks deep dives into its software technology and the applications. 

Directed Energy Deposition (DED) refers to any additive manufacturing process that uses a focused energy source, such as a plasma arc, laser or electron beam to melt and deposit material from a nozzle onto a surface. 

5-axis DED technology is opening new possibilities and finding its own niche in the manufacturing industries. The aerospace industry, for example, relies on DED for cost-effective repair of moulds and turbine blades, and tool makers use DED for manufacturing and repairing sheet metal forming tools. 

Here, ModuleWorks provides an insight into the software technology (toolpath generation, simulation and post processing) that is making DED an increasingly attractive manufacturing option and shares how the technology opens new production possibilities.

Understanding the Software Technology

Multi-Axis Tool Path Generation

Like other CAM techniques, DED uses sophisticated tool path calculation algorithms to generate efficient, collision-free machining operations from the initial CAD or mesh data. Taking a free-form machining surface as input, the volume is generated and divided into 3D slices according to the desired layer thickness. Tool paths within the layers are generated using path patterns which can be defined by path curves, intersections of guide surfaces or by automatically generated center axes. 

Propagation of the weld pool layers can be controlled by various sorting parameters. Further parameters optimise the tool path accuracy, point distribution and orientation of the laser head [CIRP Vol. 68/1, 2019, pp. 447 – 450]. The combination of the individual additive paths and the layers is automatically collision-free.

Additional features assist operators with both complex and everyday manufacturing tasks:

  • Path planning on scanned data
  • Orientation along wall structures to print areas with large overhangs
  • Fixed 6th axis to keep the orientation of the nozzle in the direction of movement for WAAM applications
  • Buildup of arbitrary curved shapes such as tube geometries

DED tool path generation software combines these features and takes the operator-defined parameters to automatically generate an additive toolpath optimised for DED manufacturing.


Multi-Axis Additive Simulation

Machine simulation is essential for catching collisions and other potential machining problems that would otherwise halt production and require operators to adjust the machining process (e.g. to redefine the workpiece zero point or reset the machine modules). Using an integrated machine simulation prevents this expensive downtime by detecting and avoiding collisions before they occur. Collisions between the part and print head, as well as printing errors, can be predicted and avoided.

DED simulation allows operators to define the shape of the tool (powder nozzle, laser) for each simulation job, and the operator-defined test points ensure a robust in-process model for the machine simulation which can be used for subsequent simulation steps. The simulation also checks for collisions between machine components, clamping devices and the in-process state of the workpiece.

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Changing Times In The Metal Cutting Industry

Changing Times In The Metal Cutting Industry

Today, workpieces need to be machined using multiple tools and fast tool change systems are becoming the norm. Article by heimatec. 

Today, workpieces generally need to be machined using multiple tools, which in turn means that tool changes are required during the machining process. In order to keep the changeover and adjustment times as short as possible, the use of fast tool change systems has become the norm. Here, heimatec, manufacturer of high-precision static and driven precision tools for lathes and machining centers, introduces its wide range of solutions for fast tool changing. 

Flexible System

Efficient manufacture is made significantly easier in two aspects. If machine downtimes can be reduced, the productive time increases automatically. By using flexible universal tools, the tool inventory can also be reduced, resulting in cost savings. 

heimatec developed the flexible heimatec.u-tec tool change system for this purpose, which allows machining companies to utilise different adapters for a wide variety of machining tasks. The driven heimatec.u-tec tools are designed with a collect chuck mount according to DIN 6499, allowing the user to use the driven tools without additional tool adapters. A special feature of the heimatec u-tec change system is the short mounting length which ensures exceptionally stable clamping of the cutting tool with low cantilever forces, leading to excellent machining results and a long service life of the cutters.

Reducing Machine Downtimes

The company has developed the easy-quick HT series specially for fast changes in the area of driven and static tools. This means different tool change inserts with market-standard tool mounts can be preset outside the tool machine and when required, can be simply, safely and quickly installed by the machine operator with one hand. With this series, machine downtimes are reduced significantly. In addition, the overall tooling costs are reduced thanks to the multiple and flexible use of the easy-quick base tools. 

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Hexagon And Authentise Partner To Deliver First Open End-To-End Software Solution For AM

Hexagon And Authentise Partner To Deliver First Open End-To-End Software Solution For AM

Hexagon’s Manufacturing Intelligence division and Authentise have partnered to extend the Additive Manufacturing (AM) control loop from the machine level to connect the end-to-end value chain from design, manufacturing operations and quality assurance to make additive manufacturing more predictable, repeatable and traceable.

Data from shopfloor manufacturing operations, engineering data from the design phase, materials properties and quality data from validation and inspection processes hold the key to automating serial production improvements and enabling design improvements. However, the technical challenge of connecting these silos and applying these data have inhibited the ability to consistently apply AM to new designs. New solutions delivered through the partnership will apply Statistical Process Control (SPC) with Machine Learning (ML) and Artificial Intelligence (AI) methods to mitigate waste and quality issues during the design phase and improve the repeatability of additive manufacturing processes within a site or between global locations.

Through the partnership, Hexagon and Authentise will build solutions to industrialise AM technology by digitising every step of the workflow from part design through production to final product and quality assurance utilising their unique stack of technology capabilities to connect the digital thread of a part and trace its pedigree. This is made possible by a shared commitment to open architectures that integrate data and automate workflows between Hexagon´s best-of-breed applications for AM and the third-party equipment and software manufacturers chose to use.

Mathieu Pérennou, Global Business Development Director Additive Manufacturing, Hexagon’s Manufacturing Intelligence division says, “Together with Authentise, we are building a next-generation framework for our customers to manage flexible, fully digitised production workflows in private cloud environments. For manufacturers, AM is a complex and changing market with many excellent tools, printers and materials to apply. We believe our open and flexible systems will enable us to respond quickly to customer’s needs and integrate with their unique environments. This will connect the data flow and help streamline their workflows in all stages of the AM process – before, during and after production and support their specific standards or compliance needs.”

Authentise is a key partner in Hexagon´s open AM ecosystem, having built an open manufacturing execution system tailored to the specific needs of additive manufacturing methods. This growing ecosystem provides a broad solution portfolio that allows Hexagon to build solutions tailored to the specific needs of customers from different industries and any level of complexity – from achieving high volume production of precision metal gears to first-time-right production of bespoke aerospace parts from composites.

Andre Wegner, CEO, Authentise says, “We are excited to combine Hexagon’s solutions with our open workflow management engine to offer a unique end-to-end solution platform. Integrating data from Hexagon’s best-of-breed software and sensors helps deliver a seamless experience for users, automation across their process, and unlocks the ability to learn from data. This partnership represents a step change for the industry – together we’re delivering the integrated digital thread for additive manufacturing that customers have sought for so long.”


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Intech Additive Solutions, Metal AM Pioneer In India, Bags Multiple Orders Worth USD 2M

Intech Additive Solutions, Metal AM pioneer In India, Bags Multiple Orders Worth USD 2M

Intech Additive Solutions Pvt Ltd.(Intech), the first Indian OEM successful in developing and supplying 3D metal printers based on laser powder bed fusion technology (LPBF) for industrial manufacturing, has bagged multiple orders in the last quarter of the FY ending 31st March,21 worth USD 2M  for its ‘Made in India’ Metal AM systems.

Intech, India’s first and only Metal Additive Manufacturer having its facility in Bengaluru,  has created history in the Metal AM industry by becoming the first Indian OEM to indigenously develop, manufacture, and sell its iFusion series of Metal AM systems, along with its Build Processing software AMBuilder and parameter optimisation software AMOptoMet – both developed in-house. These integrated systems have gained ready acceptance in the industry against stiff competition from global majors.

Intech’s multiple orders worth USD 2M  includes the sale of a combined total of six metal AM Systems, iFusion SF1, and iFusion LF1, configured with Pre-build software AMBuilder to five organisations, viz. Indo-MIM, a leading global supplier of Metal Injection Molding components catering to Aerospace, Medical, and Oil & Gas industries, Pandit Deendayal Energy University (PDEU) – for applications in Energy and Energy infrastructure, Poeir Jets- an Indian OEM for Heavy-lift Drones and two more renowned organisations in India whose names will be announced soon.

“We have focused on a steady and sustainable growth path despite the challenges of COVID and enforced lockdowns. It is exciting to see that our home grown iFusion series Metal AM systems, AM software suite AMBuilder and AMOptoMet has been well accepted and garnering increasing acclaim day by day as a better alternative to extremely expensive imported AM systems” said Sridhar Balaram, CEO of Intech Additive Solutions. “Our target industry segments are growing, and our investment strategy has kept up with the increased demand with the support of our strong team of experts in-house. We are also diversifying our team by adding innovative young professionals”

“The positive results of Q4′ 20-21 has prompted us to accelerate our investment plans in hardware, software, and consultancy. Our sales pipeline is highly promising. The market is prompting us to take a positive stand despite the looming COVID situation, which also gives us immense confidence to invest further.” said Pradeep Nair, Vice President -Hardware Sales, Intech.”We are confident and determined to establish Intech as a global OEM. Our primary task is to create an innovative ecosystem to produce metal AM products and services and embed them into mainstream manufacturing”

“Intech aspires to stay true to the principles of ‘Make in India’ and the ‘Atmanirbhar Bharat Abhiyan,’ advocating self-reliance through India’s additive manufacturing industry’s technological transformation. It also aims to be a global solution provider for Metal AM Systems and AM Software, contributing to the growth of a sustainable ecosystem for AM systems in India to compete globally and ensure AM manufactured end-user functional components for domestic and export markets.” added Sridhar Balaram.

Intech is amongst a few manufacturers globally to integrate its metal printers with its build processing software – AMBuilder and an additional software tool AMOptoMet for parameter optimisation. Combining the two software packages with Intech’s printers provides users with an end-to-end metal AM solution along with local after-sales services.


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