Next-generation metal 3D printing technology
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Release date:
2021-08-06
As the world’s first research institute to install a 13kW "Dynamic Beam Laser" (manufactured by Israel’s Civan Laser Company), IWS leverages this advanced equipment to combine multiple individual laser beams into a single, high-energy beam, enabling the rapid creation of diverse energy distribution patterns. This process continuously refines output quality, allowing for the production of components with superior precision and performance. Thanks to the precise phase shifts between the individual beams, the system can generate a variety of unique patterns—such as horseshoe, figure-eight, or ring-shaped designs—while simultaneously delivering tailored energy intensities across the entire shape.
The image above shows the dynamic beam shaping process.
While this technology is also feasible for mirrors and other optical components, oscillating mirrors require time to adjust their energy patterns. However, Civan’s laser can complete the process in just a few microseconds—over a thousand times faster than the oscillating mirror setup!
Application prospects:
As part of the European ShapeAM project, the IWS Institute will collaborate with Civan Laser and A. Kotliar Laser Welding Solutions to explore how this technology can be applied to 3D printing—encompassing the production of titanium and aluminum components for space applications, medical implants, and lightweight parts designed for mobility.
Dr. Andreas Wetzig, head of the Cutting and Joining project at the IWS Institute, said: "This laser will push the boundaries of material processing, enabling groundbreaking advancements in both medical and aerospace applications." Meanwhile, Dr. Elena Lopez, head of additive manufacturing at the institute, added: "We plan to leverage new beam shapes and control frequencies to tackle the challenges posed by crack-sensitive materials."
The team will begin testing a variety of materials and beam profiles, followed by exploring how to 3D print, cut, or join workpieces made from challenging materials and composites. They are confident that this approach will deliver faster, more precise control over the melt pool, enabling them to produce burr-free parts and cuts at speeds up to twice as fast as traditional fiber lasers.
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