Next-Generation Printing Systems: Enhanced Efficiency and Scalability

BLT has introduced major upgrades to its PBF-LB/M systems, emphasizing efficiency, reliability, and eco-consciousness. The BLT-S600 series, refined over eight years of development, now boasts a build dimension of 650mm × 650mm × 850mm, making it ideal for producing mid-sized parts and large, complex components. Innovations like the integrated build cylinder, intelligent quality detection systems, and a gas- and powder-saving circulation system ensure reliable, sustainable, and safe production.

Similarly, the BLT-S450 underwent a transformative upgrade, showcasing remarkable performance in aerospace, mold, and automotive industries. With a build dimension of 450mm × 450mm × 500mm and multi-laser configurations ranging from 4 to 8 lasers, the system enhances productivity while maintaining precision. The addition of long-life filters and automated powder circulation further cements its reputation as a cost-effective solution for industrial-scale manufacturing.

Pioneering Precision and Efficiency in Metal Additive Manufacturing

BLT has made groundbreaking progress in ultra-high-precision metal printing and thick-layer printing solutions, addressing the industry’s growing demand for intricate components and faster production cycles. The advanced PBF-LB/M technology achieves surface roughness of Ra 2-3μm and dimensional accuracy within 0.05mm, catering to applications requiring exceptional detail.

Meanwhile, BLT’s thick-layer printing technology—capable of layer thicknesses up to 150μm—delivers unparalleled efficiency, enabling high-quality serial production at significantly reduced costs.

Additionally, BLT has further refined its variable layer thickness printing technology, offering flexible layer thicknesses of 30μm, 80μm, 120μm, and 150μm depending on the specific characteristics of each part, delivering excellent forming quality and exceptional performance.

Advancing Innovation in Aerospace, Automotive, Robotics, and More

BLT’s expertise extends to diverse industries, including aerospace, medical devices, automotive components, robotics manufacturing, and heat exchanger solutions.

BLT has been a trusted partner in aerospace innovation, producing critical components for commercial rockets and satellites. Highlights include contributions to Orienspace’s “Gravity-1” commercial carrier rocket and Land Space’s ZQ-3 vertical takeoff and landing test. Additionally, BLT played an important role in the successful launch of the SmartSat-2A satellite, manufacturing large-scale parts using BLT-S1000 systems. These achievements underscore BLT’s expertise in delivering high-performance materials and optimized manufacturing processes for aerospace applications.

BLT has optimized various automotive components, including rear subframes, steering knuckles, and battery housings, reducing production time while ensuring consistent, high-quality parts that enhance production efficiency. For heat exchangers, BLT introduced three new aluminum alloy models with optimized designs, achieving a 30% increase in efficiency and meeting growing demands for energy-efficient solutions.

In the robotics sector, BLT has harnessed the transformative power of additive manufacturing to redefine the design and production of robotic components. By employing topology optimization and multi-scale configurations, BLT’s PBF-LB/M technology integrates multiple parts into single units, enhancing functionality, reducing weight, and simplifying assembly. Key applications in humanoid robots demonstrate the potential for mass production and the acceleration of next-generation robotics technologies.

BLT’s commitment to innovation is also reflected in its partnerships with universities and research institutions. The company’s systems and materials have facilitated internationally recognized breakthroughs, including studies on biomaterials for bone tissue repair, high-strength steel for cryogenic applications, and degradable porous scaffolds for large-scale bone defect treatments. Notably, a publication in Nature highlighted the exceptional fatigue resistance of titanium alloys produced using BLT equipment, supporting research on near-void-free 3D printing technology and expanding their potential in aerospace and other critical industries.

Advancing Industry Standards in Quality and Digital Manufacturing

Quality assurance remains at the heart of BLT’s innovations. The company’s enhanced quality monitoring systems integrate intelligent tools for pre-build and in-process stages, ensuring traceability and reliability. Features such as powder bed detection, defect detection platforms, and precise laser alignment have redefined industry standards.

Complementing these advancements is the upgraded BLT-MES system, a digital manufacturing solution that bridges planning and execution. With real-time data collection, production monitoring, and intelligent resource management, the system optimizes production cycles, supporting the era of mass production in metal additive manufacturing.

Expanding Global Reach and Showcasing Excellence at Industry Events

In 2024, BLT strengthened its global presence by partnering with key players across Asia, Europe, Africa, and beyond. BLT has forged deep partnerships with Lincsolution in Korea and Orix in Japan, working closely to deliver high-quality metal additive manufacturing solutions and drive technology adoption, including the launch of the ‘Tokyo 3D Lab’ showcasing multi-industry parts produced with BLT’s PBF-LB/M systems, while strategic partnerships in Europe and Africa expanded access to our technologies. In aerospace, BLT’s successful work package with Airbus Atlantic on the A320 O-Ring reinforced our expertise in high-performance, mass-production solutions. At major global industry events, from the US to Germany, South Korea, Japan, and beyond, BLT showcased innovations in automated metal 3D printing, advanced software, and real-world applications across sectors like aerospace, automotive, and consumer electronics. These efforts highlight our commitment to pushing the boundaries of metal additive manufacturing and creating value for our partners worldwide.

Shaping the Future of Additive Manufacturing

As we step into 2025, BLT celebrates a year of remarkable achievements that have redefined the possibilities of metal additive manufacturing. From cutting-edge systems and materials to groundbreaking applications across industries, BLT continues to lead innovation, delivering customized solutions that empower partners and shape the future of manufacturing. BLT looks forward to collaborating with industry leaders across various fields to drive progress and create new opportunities together.

The post BLT 2024: Pushing the Boundaries of Metal Additive Manufacturing with Cutting-Edge Technology and Innovation appeared first on Asia Pacific Metalworking Equipment News | Manufacturing | Automation | Quality Control.

Semicon industry reaps benefits from AM technology

The complex machines in the semiconductor industry depend on the precision of each individual component. Fluid and gas manifolds are examples of this fact. Because of their design, the traditional manufacture of complex fluid manifolds resulted in large, heavy parts that have abrupt fluid flow and stagnant zones and could be prone to leakage. The resulting pressure drops and flow-induced vibration have a negative influence on the semiconductor capital equipment. “With AM technology, suppliers of semicon capital equipment can avoid the traditional complex manufacturing assembly and consolidate several parts into one, improving yield and reliability”, said Andreetta. The optimization of the manifolds leads to more efficient and robust components, ultimately improving the overall performance of semiconductor manufacturing machines. AM technology of TRUMPF enables the production of components for semicon machines with enhanced stiffness and reduced weight, crucial for the high-performance demands of semiconductor manufacturing. AM-manufactured fluid manifolds have fewer pressure drops, mechanical disturbances and lower flow-induced vibration. The geometrical freedom of AM can help reduce possible leakage points and increase part performance and reliability.

Semicon industry can rely on TRUMPF AM technology

The quality required for parts used in semiconductor manufacturing machines is unparalleled, and a challenge for any manufacturing technology. With its monitoring solution for 3D printing, TRUMPF makes it possible to fulfill these requirements with automatic multi-laser alignment (AMA) and melt pool monitoring. AMA offers TruPrint users fully automated online monitoring and correction of the positioning of the laser beam paths in relation to each other – accurate down to a few micrometers. TRUMPF premiered the second release of the AMA system at Formnext 2024, which enables faster acquisition and finer correction. The patented system visually acquires the position of master and slave and corrects the second one. The procedure is performed between the production of individual layers, with an interval set by the user. TRUMPF technology also monitors the melt pool live during the printing process. “This not only ensures quality, but also potentially reduces costs,” said Andreetta. That is possible because live monitoring of the melt pool during the manufacturing process could reduce expensive non-destructive tests (NDT) such as a computer tomography (CT) scan of the component after production.

Additive manufactured manifold

The AM technology of TRUMPF enables the production of components for semicon machines with enhanced stiffness and reduced weight. (Image: TRUMPF)

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Source: Manufacturing Asia

“The potential applications of 3D printing in medicine are vast, from surgical planning and dental restoration to remote patient monitoring and telemedicine,” according to Technavio, quoted by Manufacturing Asia revealed. Meanwhile, a trend towards the field of bioprinting serves as another growth factor.

Additionally, findings from MarketsandMarkets Research revealed the global 3D printing bioprinting market vlued at US$1.3 billion in 2024, is expected to reach US$2.4 billion in 2029, growing at a compound annual growth rate (CAGR) of 12.7%. This growth is driven by advancements in 3D bioprinting technology, increased public-private partnerships, and its integration into pharmaceutical and cosmetic industries.

Key market drivers include adopting 3D bioprinting for precise tissue and organ fabrication, facilitating drug testing and personalised medicine. Opportunities lie in the rising demand for organ transplants, while biocompatibility issues and stringent sterilisation protocols present challenges.

Unlike traditional 3D printers that use plastics or metals, bioprinters utilise a computer-guided pipette to deposit living cells, known as “bioink,” to produce artificial living tissues. This capability has notable implications for organ replacement, potentially addressing donor shortages and reducing rejection risks by creating organs fit for specific needs.

Moreover, the market is also witnessing advances in other areas, including prosthetics, implants, and surgical equipment. Solutions such as stereolithography (SLA) and digital light processing are widely used in the production of customised medical devices, including orthopaedic implants and wearable medical devices. 

Furthermore, the fields of dentistry and orthodontics benefit from 3D printing, which can be utilised for dentures, bone scaffolds, and hearing aids.

“Complex medical procedures, such as implantable and non-implantable medical devices, drug testing, and organ and tissue production, are also being revolutionised by this technology,” the report added.

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Sallegger Technologies is an engineering company that builds complex machines and plants for the automotive, electronics, consumer goods, pharmaceutical, agricultural and tobacco industries, as well as for environmental and process engineering. After 27 years of innovative solutions and persistent striving for quality, Sallegger Technologies is one of the leading companies in its sector in Austria with help from Hexagon.

The company specialises in quality control in production, 3D printed parts, reverse engineering and metrology services as its main areas of application. In addition to contract manufacturing of prototypes and series, the company also offers 3D scanning and subsequent data processing, and because of this is Austria’s only provider in the field of additive manufacturing.

In product development, customers are accompanied throughout the entire development process, from international procurement of parts to CE assessment and documentation. In the search for competent partners in 3D measurement technology during at the Hexagon Scanning Day event in Spielberg – the Austrian home of Formula 1 – in autumn 2019, Sallegger Technologies found Hexagon’s structured light scanner technology together with Duwe-3d AG and PolyWorks software to offer the best overall measurement system for its tasks.

Since then, Hexagon and Duwe-3d AG have been supporting the engineering office in its projects and providing advice on the measurement, analysis and reconstruction of components.

“Sallegger Technologies is a partner of Hexagon – service requests they receive are passed on directly to us,” explains Thomas Pfeifer, Head of Innovations at Sallegger. “The fast and highly accurate SmartScan R12 optical 3D scanner is our primary measuring instrument. It is one of the leading metrology solutions for complex surface geometries and, thanks to non-contact fringe projection scanning technology, is also optimally suited for sensitive or easily deformable parts. At the same time, the fringe projection scanning technology ensures pin-sharp imaging down to the smallest detail.”

Read more here

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AM is a relatively new means of producing goods, yet has become incredibly popular around the world in a very short amount of time. More commonly known as 3D printing, AM takes raw materials in liquid form and essentially prints a component, product, or part – layer by layer. This technology has been used around the world for myriad applications from houses to, controversially, guns.

In manufacturing hubs like Vietnam, this new technology has the potential to be a changemaker. It can produce parts and components for a fraction of their traditional cost, by limiting wastage and reducing the need for labour. 

With this in mind, the potential for AM to dramatically disrupt the manufacturing industry is clear and as a result, drew significant attention in Vietnam. This is in both using AM in production processes and in developing AM technology. 

In this light, it’s not only important but can be valuable for manufacturing firms in Vietnam to understand the key industry drivers of AM — how the industry is developing, and what impact AM might have on Vietnam’s enormous manufacturing industry.

Read more here  https://shorturl.at/dsuPQ

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When deciding on the appropriate cutting tool for a particular application, it is difficult to determine whether a standard tool or a special tool is preferable. The ideal tool selection is contingent on various factors, such as the nature of the business situation, the manufacturing program, the production type, and sometimes personal preferences.

Versatility Vs Precision

Standard cutting tools, produced by a specific tool manufacturer, offer high versatility and are appropriate for machining a diverse range of parts that come in different shapes. Furthermore, the tool exhibits excellent performance capabilities when cutting various engineering materials.

To ensure seamless production processes, it is crucial to have the cutting tools delivered in a timely manner. This is why standard tools are the foundation of tool stock management on metalworking production floors.

A special cutting tool is designed for specific operations on a particular part, made of a specific material, and used on a machine that requires a specific work holding fixture. This custom-engineered tooling solution aims to provide the best possible performance and outcome.

However, there is a downside to this solution as it limits the tool’s versatility, making it less adaptable to different applications. As a result, special tools are primarily used for high-volume mass production, especially in the automotive industry.

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Additive manufacturing was once considered a niche concept, has now become an awe-inspiring force, dramatically altering the industrial landscape. The integration of 3D metal printing with advanced materials, software, and automation has opened up new possibilities and redefined traditional approaches to design and production.

A Concise Chronicle 3D Metalworking

The world witnessed the inception of a groundbreaking concept, 3D printing in the 1980s. Initially centered on plastic materials, this revolutionary technology soon set its sights on a more ambitious target: metals.

Thus, the advent of 3D metal printing, also referred to as metal additive manufacturing, marked a turning point in the manufacturing landscape. At its nascent stage, 3D metal printing encountered a series of hurdles, including constrained material options, steep expenses, and limited scalability. However, persistent research and development efforts paved the way for substantial improvements and broadened its applications.

Empowering The Tool Manufacturing Industry

The tool manufacturing sector is experiencing a revolution with 3D metalworking. Designing and producing intricate tooling components with improved durability and performance is now possible. This transformation empowers toolmakers to deliver high-quality products, enhance productivity, and optimise overall manufacturing processes.

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Total worldwide spending in construction was US$11.4 trillion in 2018 and is expected to increase to US$14 trillion by 2025. Being huge economic contributors, the industry is yet plagued by low productivity, technological advances, minimum automation and robotic usage.

There is a strong link between the level of digitisation and its productivity improvement. The U.S. construction industry invested only 1.5% of value added on technology — much lower than the manufacturing industry (3.3%) and the overall average in the economy of 3.6%.

Various analyses portrayed that productivity in construction remained almost the same over the last few decades, whereas that in manufacturing nearly doubled. Recent studies depict the construction industry is gradually embedding automated systems and robotic usages, mostly in the research and development with very limited practical applications.

Virtual reality, augmented reality, mixed reality, drones, robotic arms, lesser scanning/photogrammetry, 3D printing (3DP) are the several forms of automation being researched and used in construction. Nevertheless, most of these automated technologies are particularly used for some specific projects.

Considering the unique nature of construction, these technologies are not readily applicable or repeatable to multiple construction projects unlike manufacturing productions.

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Standard manufacturing methods lost their traction to advanced ones for profitability. Hybrid manufacturing combines two or more distinct processes in a single piece of equipment. There are several types of hybrid manufacturing, although the most common combines laser additive manufacturing (AM) and 5-axis machining processes.

Machining with 5 or More Axis

5-axis machining, in addition to the X, Y, and Z axes, has two rotary axes, which greatly improves machining efficiency and accuracy. This is commonly used to machine blades, rotors, dies, molds and propellers, among others. It is hence the most important piece of equipment related to cutting—allowing the production of final components with more complex shapes impossible to obtain in a 3- or 4-axis m Figure 7 exemplifies a 5-axis tool with table tilt A-C and X, Y, and Z axis, showing the flexibility presented by these systems.

My et al. showed a mathematical model that analyses and compares the kinematic performance of six configurations of 5-axis machines. Xu et al. emphasised the need to avoid changing tool orientation in 5-axis machining, and proposed a smoothing method oriented to kinematic performance.

Using double-flank milling, Bizzarri et al. investigated fabricating screw rotors, since it was applied in 5-axis flank machining. Double-flank milling is feasible as a designed tool for symmetrical profiles. Bo et al. demonstrated a customised tool for machining narrow and curved regions with high precision, validated the algorithm using commercial software.

Prabha et al. integrated the Unigraphics NX6 CAD/CAM software into 5-axis CNC machines, to machine steam turbine blades, and made the measurement through 3D coordinates, observing great efficiency in relation to dimensional accuracy. Huang et al. emphasised the geometric errors in 5-axis machine despite the machine precision, and defined two models: “Rotary axis component displacement” and “Rotary axis line displacement” — analysing machining of five axes with discrepant results. 5-axis machining’s accuracy determines the processing success, manufacturing parts and products; possessing great advantage in flexibility and efficiency.

Read more here —–> https://t.ly/Jk0_0

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“Additive Manufacturing (AM) is disrupting the traditional manufacturing industry, including the automotive sector. With the increasing need for product customisation, environmental regulations, and supply chain instability, AM is an emerging game-changer in the automotive industry. The rise of generative design and AM is transforming the way automotive components are designed and produced. We are witnessing a shift from mass production to on-demand manufacturing, and this has enabled manufacturers to reduce costs, improve efficiency, and gain a competitive edge.

“AM is opening innovative design possibilities, enabling manufacturers to create complex geometries previously impossible to manufacture using traditional methods. This is just the beginning, and I believe we will see more disruptive changes in the automotive industry with the continued adoption of Additive Manufacturing technology,” DTS Technology Director Chan Wei Eik, noted.

Chan identifies an example on “a leading car manufacturer recently faced the challenge of improving production efficiency while maintaining high-quality components, and the answer lays in Additive Manufacturing. By adopting this revolutionary technology, the company not only streamlined its manufacturing process, but also gained a significant advantage over its competitors.

The company was grappling with a time-consuming and expensive traditional manufacturing process for its car components, leading to long lead times, a high material wastage, and difficulty in creating complex geometries. This left them struggling to keep up with the dynamic demands of their customers and at risk of falling behind competitors.”

Read more here —–> https://t.ly/ciRMp

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