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Direct manufacturing. Going way beyond rapid prototyping.

"Manufacturers finally have a true Direct Manufacturing solution that will save money and boost efficiency," says Scott Phillips, president of Sciaky.

"Sciaky's DM solution is the first robust, fully programmable means of achieving near-net shape parts, ready to undergo finish machining." Sciaky is a leading manufacturer of electron beam, resistance, and arc welding systems for the aerospace, manufacturing, and defense markets. The company has been working with EBFFF (Electron Beam Free Form Fabrication) technology for many years and has manufactured solutions using a wide range of materials, including titanium, nickel, stainless steel, and refractory alloys.

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The company has recently come up with a revolutionary technique which allows for true Direct Manufacturing of assemblies and structures. Sciaky's Direct Manufacturing (DM) technique uses Electron Beam or Arc (TIG) welding technologies, and offers many cost-saving advantages. According to the company, "the technology will impact your profits, your

efficiency, the entire way you look at your manufacturing and rapid prototyping processes." With Sciaky's exclusive DM process, companies can have functional prototypes, even manufactured parts, when they need them, at a fraction of the cost of traditional manufacturing and without the long lead times.

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"Whatever metals you choose, for virtually any configuration, Sciaky's DM technology is the low-cost answer to part development and manufacturing. Whether you need a prototype part for prove out, or a full-scale production run of virtually any other type of component, in large or small batches, Sciaky has the flexibility and muscle to help you achieve your manufacturing goals," says Phillips.

Interested parties can watch a demonstration of Sciaky's exclusive technology on display at the FABTECH International & AWS Welding Show at McCormick Place in Chicago. The show will take place from November 15-18, 2009. Sciaky's booth is number 39053.

DM with Electron Beam

With Sciaky's flexible DM process, a part can be designed on virtually any CAD system. The part program is then downloaded into Sciaky's exclusive control system. Using wire-feed, the fully articulated, moving electron beam gun deposits the metal, layer by layer, until the part is complete. With Sciaky's DM process, sustained deposition rates of 15 to 40 pounds of metal per hour can be achieved. Depending on the part being manufactured, much higher rates are readily attainable.

DM with ARC (TIG)

An engine manufacturer recently came to Sciaky with a special challenge to create a better piston head that could withstand significantly higher temperatures than standard.

Sciaky responded to the challenge by modifying its Arc (TIG) DM process, and "coating" the piston head with Inconel using a proprietary TIG technique. The result was a more robust piston with nearly a 30% longer lifespan.

For more information, visit sciaky.com.

SPECIFIC ADVANTAGES OF EBFFF

Fabricate OEM Structures and Equipment beyond prototype stage

* Machining Preforms

--Save 80-90% of metal purchase of hogout

--Save 80% of overall delivery time

--Eliminate rough machining steps and one step over hogouts

--Go directly to final machining step

* Less costly than forgings

--Eliminates blocker die series and repeated heat treatments

--Eliminates shaper dies and heat treatments

--Cuts 90% of delivery time delays from making dies

--Eliminates 80-90% of rough machining over forging

--Go directly to final machining step

* Less costly than castings

--Saves making molds and skips molten metals issues

--Cuts 90% off delivery times

* Ideal for meeting rapid response requirements and small lot orders

Facilitate Repair and Refurbishment

* Repair of mis-machined parts in manufacturing

--Additive process can recover high value parts

* Can provide "Parts Now" and in-the-field repairs at remote repair stations

--Adds to greater availability of assets

--Eliminate storage or platforms awaiting repair parts and delivery

--Permits quick refurbishment of legacy systems

--Permits recovery and re-deployment of high value components

--Minimizes inventories and eliminates large lot re-supply requirements

Fabricate Hybrid Structures

* Meets future requirements of "Tailored" structures not achievable by legacy forging, casting, or machining of monolithic materials

* Only additive method able to provide hybrid structures with lugs and bosses without high fault zones associated with castings

* Ability to vary alloy and chemistry throughout the landscape of a component to vary strength, fatigue performance, toughness etc. throughout a part's geometry

* Potential weight savings over monolithic structures

* Create unique part properties.

COMPETITIVE STRATEGIES FOR USE OF EBFFF

* Increase machine shop yield

* Reduce machining requirements

* Reduce shop capital investments for rough machine tooling

* Faster deliveries of small lot structures

* Eliminate waiting for dies, molds, and supplier delays

* Provides competitive pricing negotiation leverage

* Added advantage in lighter structures with faster delivery over competition

* Government already using and accepting parts manufactured by additive manufacturing processes
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Title Annotation:innovation
Comment:Direct manufacturing. Going way beyond rapid prototyping.(innovation)
Author:Barclay, Steve
Publication:Automotive Industries
Geographic Code:1USA
Date:Sep 22, 2009
Words:752
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