MetalFAB1

The MetalFAB1 is a DMLS 3D printer from Additive Industries with a 420 x 420 x 400 mm build volume.

Specifications

Lasers: Up to four independent 500 W fiber lasers (2000 W total), λ=1070 nm; full coverage of 420×420 mm build area.

Scanners: Four galvo scanners with coordinated scan strategy; 6 overlap zones with automated calibration in AMSUITE.

Platform: Build plate with heater up to 300°C (exceeds competitors); automated transfer between modules.

Modular architecture: 2–11 modules: Print Module + Thermal Treatment Module + Depowdering Module + Storage; fully automated workflow.

Build volume: 420 × 420 × 400 mm (70.6 L: among the largest in LPBF class).

In-situ monitoring: Optical tomography and melt pool monitoring for layer-by-layer traceability.

Calibration

4-laser galvo synchronization: AMSUITE automated calibration; CT verification of 6 overlap zones.

Module transfer: Alignment when adding module; O₂ check after each transfer.

Platform heater 300°C: 5-point thermocouples; uniformity ± 5°C.

Powder system: PSD + Hall flow after each recycling cycle; verify dosing valves.

In-situ monitoring baseline: Reference build for new material; ± 15% sensor tolerance for AS9100 traceability.

Common defects

Module contamination: Transfer seals → inspect and verify O₂ after each module transfer.

Multi-laser seam defects: 6 overlap zones → AMSUITE auto-calibration + CT test after parameter changes.

In-situ thermal distortion: Non-uniform cooling → optimize thermal cycle in AMSUITE; add stress relief step.

Incomplete depowdering: Channels < 3 mm → design drain holes in DfAM phase; CT verification after depowdering.

What it is used for

Aerospace (AS9100/NADCAP): Ti-6Al-4V and Inconel parts with full traceability from build to thermal treatment.

Space hardware: Batch production of rocket components with integrated thermal treatment.

Medical Class III: Automated process with FDA/MDR documentation; Safran and Airbus validated processes.