{"id":180325,"date":"2021-03-12T02:34:09","date_gmt":"2021-03-12T02:34:09","guid":{"rendered":"http:\/\/facfox.com\/news\/?p=180325"},"modified":"2021-04-06T03:23:26","modified_gmt":"2021-04-06T03:23:26","slug":"exone-and-ford-strike-back-with-automotive-specific-aluminum-binder-jetting-and-high-density-sintering","status":"publish","type":"post","link":"https:\/\/facfox.com\/news\/exone-and-ford-strike-back-with-automotive-specific-aluminum-binder-jetting-and-high-density-sintering\/","title":{"rendered":"ExOne and Ford Strike Back with Automotive-specific Aluminum Binder Jetting and High-density Sintering"},"content":{"rendered":"

The hottest competition is in metal binder jetting and so it happens that, on the same day, two leaders in this field make a comparable breakthrough announcement: the ability to 3D print<\/a> aluminum 6061 alloy by binder jetting and, more importantly, to proficiently sinter it. ExOne achieved this aluminum binder jetting breakthrough by working with Ford Motors Company on a new patent-pending process.<\/p>\n

Aluminum 6061 is one of the most commonly used aluminum alloys in the world. It has many general purpose application<\/a>s and is commonly used in aerospace<\/a> and automotive<\/a> for large-scale production application<\/a>s that are considered an ideal target for metal binder jetting production processes, however, it could not be easily and proficiently sintered. However, it only took a couple of years of serious development on metal binder jetting industrialization to achieve this goal.<\/p>\n

We sometimes wonder why additive manufacturing is so much more exciting than all other manufacturing processes\u2014even highly automated ones\u2014so much so that many professionals and media involved in this field feel a true passion for it. Almost like gaming or digital entertainment. It\u2019s because, although sometimes it doesn\u2019t seem like it from the outside, innovation goes at breakneck speed in AM and the technology grows at Moore\u2019s Law-like rates.<\/p>\n

<\/p>\n

The new patent-pending process developed by ExOne and Ford Motor Co. for binder jetting 6061 aluminum can deliver final part<\/a>s with 99% density. In the project, which was co-founded by Ford and ExOne, a team of engineers, material scientists, and manufacturing experts developed a process for rapid and reliable binder jet 3D print<\/a>ing<\/a> and sintering of aluminum that delivers properties comparable to die casting.<\/p>\n

Delivering a commercially viable achievement in this area has evaded researchers for more than a decade. Collaborative and individual patents are expected to be filed by Ford and ExOne as a result of this ongoing project.<\/p>\n

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Some aluminum alloys can be 3D print<\/a>ed today using lasers, but the process is much slower than the one developed by Ford and ExOne. The new process is expected to increase Ford\u2019s efficiency by allowing the company to affordably produce complex part<\/a>s uniquely designed for additive manufacturing, which enables size and weight reductions, part<\/a> consolidation, and performance improvements.<\/p>\n

\u201cThis is a breakthrough in making 3D print<\/a>ed and sintered part<\/a>s for the auto industry,\u201d said Harold Sears, Ford technical leader for additive manufacturing. \u201cWhile the 3D-printing process is very different than stamping body panels, we understand the behavior of aluminum better today, as well as its value in light-weighting vehicle<\/a>s. High-speed aluminum 3D print<\/a>ing<\/a> paves the way for other opportunities that we\u2019re just now start<\/a>ing to take a look at because of the ability to do complex part<\/a>s with aluminum that previously weren\u2019t possible. It\u2019s really opening doors for other opportunities.\u201d<\/p>\n

<\/p>\n

\u201cDeveloping a fast, affordable, and easy way to 3D print<\/a> aluminum with traditional material properties is a critical step toward light-weighting more products and delivering a more sustainable future,\u201d said John Hart<\/a>ner, ExOne CEO. \u201cOur world-class engineers and scientists are focused on solving the toughest problems with 3D print<\/a>ing<\/a> technology, and this achievement is a real win for all of us.\u201d<\/p>\n

The new innovation came about through the process of binder jetting, widely regarded as the fastest method of metal 3D print<\/a>ing<\/a> for high-volume output. It uses a digital file to quickly inkjet a binder into a bed of powder part<\/a>icles such as metal, sand, or ceramic to create a solid part<\/a>, one thin layer at a time. When printing metals, the final bound metal part<\/a> must be sintered in a furnace to fuse the part<\/a>icles together into a solid object. The heating process reinforces the strength and integrity of the metal, and while the process for sintering stainless steel is well understood, achieving high densities greater than 99 percent is an industry breakthrough for aluminum.<\/p>\n

The Ford-ExOne joint development project was first initiated in 2019. Ford has led the final material and repeatability testing to verify its accuracy. The cross-functional Ford-ExOne team is actively working on designs to use the new material and process.<\/p>\n

The relationship between Ford and ExOne goes back to the early 2000s when Ford purchased several of ExOne\u2019s first industrial sand 3D print<\/a>ers in the United States to create sand molds and cores for metal casting. ExOne 3D print<\/a>ers are among a wide range of technologies featured in Ford\u2019s Advanced Manufacturing Center in Redford, Mich., with additional ExOne printers in Ford\u2019s UK facilities.<\/p>\n

<\/div>\n

 <\/p>\n

* This article is reprinted from 3D Printing Media Network<\/a>. If you are involved in infringement, please contact us to delete it.<\/p>\n

<\/i> Author: Davide Sher<\/p>\n","protected":false},"excerpt":{"rendered":"

The hottest competition is in metal binder jetting and so it happens that, on the same day, two leaders in this field make a comparable breakthrough announcement: the ability to 3D print aluminum 6061 alloy by binder jetting and, more importantly, to proficiently sinter it. ExOne achieved this aluminum binder jetting breakthrough by working with Ford Motors Company on a new patent-pending process.<\/p>\n","protected":false},"author":3,"featured_media":184748,"comment_status":"open","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"_monsterinsights_skip_tracking":false,"_monsterinsights_sitenote_active":false,"_monsterinsights_sitenote_note":"","_monsterinsights_sitenote_category":0,"fifu_image_url":"https:\/\/facfox.com\/news\/wp-content\/uploads\/2021\/3\/yQFFFj.png","fifu_image_alt":"ExOne and Ford Strike Back with Automotive-specific Aluminum Binder Jetting and High-density Sintering","footnotes":""},"categories":[383],"tags":[24,64,252,145,54],"class_list":["post-180325","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-automotive","tag-3d-printing","tag-aerospace","tag-aluminum","tag-automotive","tag-metal"],"yoast_head":"\nExOne and Ford Strike Back with Automotive-specific Aluminum Binder Jetting and High-density Sintering - FacFox News<\/title>\n<meta name=\"description\" content=\"The hottest competition is in metal binder jetting and so it happens that, on the same day, two leaders in this field make a comparable breakthrough announcement: the ability to 3D print aluminum 6061 alloy by binder jetting and, more importantly, to proficiently sinter it. 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