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Sciaky to Deliver Large, Industrial-Scale Metal 3D Printer to Airbus

Sciaky’s Electron Beam Additive Manufacturing (EBAM™) system will help the leading aircraft manufacturer save significant time and cost on the production of large titanium structural parts

Chicago, Illinois – Sciaky, Inc., a subsidiary of Phillips Service Industries, Inc. (PSI) and leading provider of metal additive manufacturing (AM) solutions, and Lyon (France) based x3D Group SAS, European Provider of AM solutions & services, announced today that Airbus will take delivery of a state-of-the-art Electron Beam Additive Manufacturing (EBAM™) VX-110 System in December 2016. The renowned aircraft manufacturer will utilize Sciaky’s industrial-scale metal 3D printing system to produce large structural parts made of titanium.
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Sciaky’s EBAM process combines computer-aided design (CAD), additive manufacturing processing principles, and an electron beam heat source. Starting with a 3D model from a CAD program, Sciaky’s fully-articulated, moving electron beam gun deposits metal via wire feedstock, layer by layer, until the part reaches near-net shape. From there, the near-net shape part requires heat treatment and post-production machining. In the end, there is minimal material waste.

mmddd“When it comes to large parts made of complex metals & alloys, EBAM technology helps our customers solve two major manufacturing challenges: lead times are slashed from weeks to days, and costs are reduced by more than half”, says Kamal BOUNOUARA, president of x3D Group & EBAM consultant for Western Europe.

Sciaky brings quality and control together in one step with IRISS™ – the Interlayer Real-time Imaging and Sensing System. IRISS is the only real-time monitoring and control system in the metal 3D printing market that can sense and digitally self-adjust metal deposition with precision and repeatability. This closed-loop control is the primary reason that Sciaky’s EBAM 3D printing process delivers consistent part geometry, mechanical properties, microstructure, and metal chemistry, from the first part to the last.

As mentioned above, EBAM utilizes wire feedstock, which can accommodate a wide variety of metals and refractory alloys, such as titanium, tantalum, niobium, tungsten, Inconel, and stainless steels. Sciaky’s EBAM 110 System has a work envelope of 70” (1778 mm) x 47” (1194 mm) x 63” (1600 mm).

“Sciaky is very proud to partner with a world-class innovator like Airbus,” said Bob Phillips, Vice President of Marketing for Sciaky, Inc. “We all know that metal 3D printing technology is going to revolutionize manufacturing in the aerospace industry, and Sciaky is committed to being at the forefront of this movement.”

As the most widely scalable metal 3D printing solution in the industry in terms of work envelope, Sciaky’s lineup of EBAM systems can produce parts ranging from 8 inches (203 mm) to 19 feet (5.79 meters) in length. EBAM is also the fastest deposition process in the metal additive manufacturing market, with gross deposition rates ranging from 7 to 20 lbs. (3.18 to 9.07 kg) of metal per hour.llll

To learn more about x3D Group & Sciaky, please visit www.x3d-ebam.com and www.sciaky.com

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About Sciaky, Inc.

Sciaky, Inc., a subsidiary of Phillips Service Industries, is a world leader in metal 3D printing solutions. Our exclusive Electron Beam Additive Manufacturing (EBAM™) process is the fastest, most cost-effective 3D printing process in the market for large-scale metal parts, allowing manufacturers to save significant time and money over traditional manufacturing and rapid prototyping processes. Sciaky also provides industry-leading electron beam (EB) and advanced arc welding systems, as well as the most robust EB job shop welding services in the world, for the aerospace, defense, automotive, healthcare and other manufacturing industries. Our welding equipment meets rigid military specifications to manufacture items such as airframes, landing gear, jet engines, guided missiles and vehicle parts.

About x3D Group SAS

Located in Lyon (France), x3D Group specializes in the Additive Manufacturing sector, offering Solutions, Services and Consulting. Its x3D-Pro branch retails a disruptive High Speed 3D Printing technology for plastic visual & functional prototyping, while its x3D-Print.com platform offers 3D Printing services online. Its president Kamal BOUNOUARA helps industrial companies in Aero, Defense, Nuclear and other sectors to integrate EBAM technology in their production strategy.

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Sciaky, Inc. to Provide Turnkey Electron Beam Additive Manufacturing System to Lockheed Martin Space Systems

EBAM® System will help Lockheed Martin reduce time and cost on production of titanium propulsion tanks

September 22, 2014

Chicago, IllinoisSciaky, Inc., a subsidiary of Phillips Service Industries, Inc. (PSI) and provider of large-scale additive manufacturing solutions, announced today that it recently received a purchase order from Lockheed Martin Space Systems to provide a turnkey electron beam additive manufacturing (EBAM®) system. The EBAM system will help Lockheed Martin reduce time and cost on the production of titanium propulsion tanks.

On July 10, Sciaky announced the availability of EBAM systems to the marketplace. This is the second multi-million dollar order from a major global manufacturing company since the announcement. In addition, Sciaky is working with over a dozen other companies and entities within the aerospace, defense and manufacturing sectors to provide EBAM systems for their unique needs.

Lockheed Martin Space Systems designs, develops, tests, manufactures and operates a full spectrum of advanced-technology systems for national security, civil and commercial customers. Chief products include human space flight systems; a full range of remote sensing, navigation, meteorological and communications satellites and instruments; space observatories and interplanetary spacecraft; laser radar; fleet ballistic missiles; and missile defense systems.

Sciaky’s EBAM process combines computer-aided design (CAD), electron beam manufacturing technology and layer-additive processing. Starting with a 3D model from a CAD program, Sciaky’s fully-articulated, moving electron beam gun deposits metal (via wire feedstock), layer by layer, until the part reaches near-net shape. From there, the near-net shape part requires minor post-production machining. The 110” x 110” x 110” (L x W x H) build envelope of the EBAM system will allow Lockheed Martin to produce large titanium parts, with virtually no waste.

“Sciaky is proud to partner with a progressive leader like Lockheed Martin Space Systems” said Mike Riesen, general manager of Sciaky, Inc. “Sciaky’s EBAM technology will help Lockheed Martin significantly reduce material costs, lead times, and machining times.”

Besides offering innovative additive manufacturing solutions for metal parts, Sciaky provides state-of-the-art electron beam and advanced arc welding systems, as well as job shop/contract welding services, for manufacturers in the aerospace, defense, automotive, and healthcare industries. Sciaky’s welding equipment meets rigid military specifications to manufacture items such as airframes, landing gear, jet engines, guided missiles and vehicle parts.

For information about Sciaky’s additive manufacturing systems, visit http://www.sciaky.com/additive_manufacturing.html

Sciaky’s Electron Beam Additive Manufacturing (EBAM®) Technology Helps Submarine Manufacturer Save Significant Time and Cost By 3D Printing a Titanium Variable Ballast (VB) Tank

With this new and exciting use of EBAM, Sciaky is the world’s only industrial-scale metal AM provider with approved parts in land, sea, air, and space applications

CHICAGO, Illinois | January 31, 2017

ISE Arctic Explorer AUV
(Above) ISE’s Arctic Explorer AUV

Sciaky, Inc., a subsidiary of Phillips Service Industries, Inc. (PSI), and leading provider of metal 3D printing solutions, announced today that announced today that its Electron Beam Additive Manufacturing (EBAM®) technology helped International Submarine Engineering (ISE), Ltd. cut significant time and cost from the production of a titanium Variable Ballast (VB) tank versus the traditional manufacturing process.

ISE approached Sciaky after the closure of its former supplier, an overseas titanium forging facility that produced propellant tanks for the Russian space program. ISE did not want to risk further delays in their exploration plans, so they reached out to Sciaky, after learning that Sciaky had 3D printed titanium propellant tanks for Lockheed Martin Space Systems in 2015.

The engineers and project management team at Sciaky immediately put together an aggressive plan to produce a new titanium VB tank for ISE using Sciaky’s patented EBAM 3D printing process. In the end, Sciaky helped ISE reduce production time from 16 weeks to 8 weeks, as well as reduce overall costs as compared to retooling with a new forging supplier. In addition, the VB tank created with Sciaky’s EBAM process passed the same vigorous qualification testing as the tank previously created with the forging process. ISE now plans to 3D print other critical titanium parts with Sciaky’s EBAM process.
(Above) Titanium Variable Ballast (VB) Tank
created with Sciaky’s EBAM 3D printing process.

The titanium VB tank is a sub-system of ISE’s Arctic Explorer Autonomous Underwater Vehicle (AUV) class of vehicles. ISE previously built two Arctic Explorers for Natural Resources Canada/Defence Research and Development Canada (DRDC) to map the sea floor underneath the Arctic ice shelf in support of Canada’s claim under Article 76 of the United Nations Convention on the Law of the Sea. The Arctic Explorer is the largest of the Explorer AUV class, measuring over seven meters (nearly 23 feet) long and weighing over 2000 kilograms (4409 pounds). It can be launched from a ship or through an ice-hole and the modular sections can be separated for transportation. Its unique VB system enables it to park on the sea floor or hold itself on the underside of the ice during missions. Rated to 5,000 meters (roughly 3.11 miles) depth, the Arctic Explorer is designed to remain underwater between missions for extended periods of time. A small Remotely Operated Vehicle (ROV) conducts all servicing and charging after the AUV is attached to a docking head.

The VB tank 3D printed with Sciaky’s EBAM process will be installed onboard a new Arctic Explorer AUV that is scheduled to be delivered to the University of Tasmania in the spring of 2017. This new Explorer AUV will be deployed in Antarctica after extensive trials and training operations.

“Sciaky is proud to help ISE cut production time by 50 percent and reduce costs by 3D printing their titanium VB tank with our one-of-a-kind EBAM process,” said Bob Phillips, Vice President of Marketing for Sciaky, Inc. “Our industry-leading EBAM technology is the world’s only industrial-scale metal 3D printing solution with approved parts for land, sea, air, and space applications.”

As the most widely scalable metal 3D printing solution in the industry in terms of work envelope, Sciaky’s lineup of EBAM systems can produce parts ranging from 8 inches (203 mm) to 19 feet (5.79 meters) in length. EBAM is also the fastest deposition process in the metal additive manufacturing market, with gross deposition rates ranging from seven to 20 lbs. (3.18 to 9.07 kg) of metal per hour. EBAM brings quality and control together with IRISS™ – the Interlayer Real-time Imaging and Sensing System, which is the only real-time monitoring and control system in the metal 3D printing market that can sense and digitally self-adjust metal deposition with precision and repeatability. This innovative closed-loop control is the primary reason that Sciaky’s EBAM 3D printing process delivers consistent part geometry, mechanical properties, microstructure, and metal chemistry, from the first part to the last.

You can follow Sciaky on Twitter, Facebook, Google+, YouTube and LinkedIn.


About Sciaky, Inc.

Sciaky, Inc., a subsidiary of Phillips Service Industries, is a world leader in metal 3D printing solutions. Our exclusive Electron Beam Additive Manufacturing (EBAM™) process is the fastest, most cost-effective 3D printing process in the market for large-scale metal parts, allowing manufacturers to save significant time and money over traditional manufacturing and rapid prototyping processes. Sciaky also provides industry-leading electron beam (EB) and advanced arc welding systems, as well as the most robust EB job shop welding services in the world, for the aerospace, defense, automotive, healthcare and other manufacturing industries. Our welding equipment meets rigid military specifications to manufacture items such as airframes, landing gear, jet engines, guided missiles and vehicle parts.

About International Submarine Engineering, Ltd.

International Submarine Engineering (ISE), Ltd. and International Submarine Engineering Research (ISER) are world leaders in the design and integration of underwater vehicle systems that include AUVs, ROVs, and HOVs. In addition, ISE manufactures assorted terrestrial robotic systems. Since 1974, these companies have developed unique capabilities for turning diverse conceptual requirements into functional solutions for a broad customer base. To meet individual customer needs, ISE/ISER utilize a multidisciplinary engineering approach to provide integrated solutions that meet operationally and functionally complex programs. ISE/ISER are ISO 9001 certified.

Sciaky’s Electron Beam Additive Manufacturing (EBAM) Technology Helps Major Automotive Manufacturer Cut Significant Time and Costs with the Creation and Repair of Tooling and Stamping Dies

CHICAGO, Illinois  |  Sept. 27, 2016

Electron Beam Additive Manufacturing Automotive Tooling Solution
(Above) An example of a forming die that can be created with Sciaky’s EBAM technology

Sciaky, Inc., a subsidiary of Phillips Service Industries, Inc. (PSI), and leading provider of metal 3D printing solutions, announced today that its Electron Beam Additive Manufacturing (EBAM®) technology helped a major automotive manufacturer cut significant time and costs with the creation and repair of several tooling and stamping dies.

The manufacturer leveraged Sciaky’s EBAM to deposit complicated tooling features, as well as perform customized repairs and cladding operations for several high-volume parts. After a successful proof of concept (POC) engagement, the 3D printed tool was put into production.

“Sciaky’s EBAM technology is not limited to titanium parts and aerospace applications,” said Bob Phillips, Vice President of Phillips Service Industries, Inc. “We have provided 3D printed solutions to customers in a variety of industries like automotive, agricultural, defense, nuclear, oil & gas, and sea exploration using a wide variety of metals like stainless steel, tantalum, tungsten, Inconel, and niobium.”

In July 2016, EWI, a leading North American engineering and technology organization dedicated to developing, testing, and implementing advanced manufacturing technologies, purchased an EBAM system to produce prototype parts for high-tech manufacturers in a variety of industries across the U.S. Sciaky and EWI will work together to co-market their extensive metal 3D printing capabilities to the marketplace.

As the most widely scalable, metal 3D printing solution in the industry (in terms of work envelope), Sciaky’s EBAM systems can produce parts ranging from 8 inches (203 mm) to 19 feet (5.79 meters) in length, but can also manufacture smaller and larger parts, depending on the application. EBAM is also the fastest deposition process in the metal additive manufacturing market, with gross deposition rates ranging from 7 to 20 lbs. (3.18 to 9.07 kg) of metal per hour. Plus, with a dual wirefeed option, two different metal alloys can be combined into a single melt pool to create “custom alloy” parts or ingots. In addition, the mixture ratio of the two materials can be changed to create “graded” parts or structures.

Sciaky to Deliver Industry-Leading Electron Beam Additive Manufacturing System to EWI

Sciaky and EWI will work together to 3D-print metal prototype parts for a wide range of manufacturers

Chicago, Illinois – Sciaky, Inc., a subsidiary of Phillips Service Industries, Inc. (PSI), and leading provider of metal additive manufacturing (AM) solutions, announced today that EWI has purchased an industry-leading Electron Beam Additive Manufacturing (EBAM®) system. EWI is a leading engineering and technology organization in North America dedicated to developing, testing, and implementing advanced manufacturing technologies for industry.

Sciaky and EWI will work together to produce prototype parts for high-tech manufacturers in a variety of industries across the U.S. Both companies plan to co-market their extensive metal 3D printing capabilities to the marketplace.

“Sciaky is very excited to work with an innovator like EWI,” said Mike Riesen, General Manager of Sciaky, Inc. “Beyond simply selling an EBAM system to EWI, Sciaky will collaborate with EWI to advance and promote EBAM technology into mutual fields of interest. New applications and solutions will surely be discovered under this exciting partnership.”

As the most widely scalable, metal 3D printing solution in the industry (in terms of work envelope), Sciaky’s EBAM systems can produce parts ranging from 8 inches (203 mm) to 19 feet (5.79 meters) in length, but can also manufacture smaller and larger parts, depending on the application. EBAM is also the fastest deposition process in the metal additive manufacturing market, with gross deposition rates ranging from 7 to 20 lbs. (3.18 to 9.07 kg) of metal per hour. Plus, with a dual wirefeed option, two different metal alloys can be combined into a single melt pool to create “custom alloy” parts or ingots. In addition, the mixture ratio of the two materials can be changed to create “graded” parts or structures.

About EWI
EWI is the leading engineering and technology organization in North America dedicated to developing, testing, and implementing advanced manufacturing technologies for industry. Since 1984, EWI has offered applied research, manufacturing support, and strategic services to leaders in the aerospace, automotive, consumer electronic, medical, energy, government and defense, and heavy manufacturing sectors. The company matches its expertise to the needs of forward-thinking manufacturers to serve as a valuable extension of clients’ innovation and R&D teams. Through this collaboration, EWI provides premium, game-changing solutions that deliver a competitive advantage in the global marketplace. To learn more, visit www.ewi.org, email info@ewi.org, or call 614.688.5000.

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