Calibur3

The Calibur3 is an EBM 3D printer from Wayland Additive with a 300 x 300 x 450 mm build volume.

Specifications

Electron Gun: 6 kW peak power; 60 kV acceleration voltage; minimum spot size ≤ 200 µm.

Process (NeuBeam): Hot-part EB-PBF: heat applied only to the part, not the entire powder bed. Result: zero sinter cake, zero residual stress.

Build Volume: 300 × 300 × 450 mm: mid-size for EBM; adequate for aerospace brackets and orthopaedic implants.

Chamber & Vacuum: Process vacuum ≤ 1×10⁻⁴ mbar; helium backfill option.

In-process Monitoring: Structured light + electron imaging + high-speed IR camera: three parallel data streams per layer.

Layer Thickness: 50–200 µm; typical production mode 80–120 µm.

Calibration

Beam Zeroing: Focus and aberration correction at cold start; test spot ≤ 200 µm.

NeuBeam Charge Neutralisation: Alloy-specific parameter set: supplied by Wayland for standard materials.

IR/NIR Sensor Calibration: Cross-check against embedded thermocouples at three power levels.

Vacuum Cycle Check: Confirm ≤ 1×10⁻⁴ mbar before each session: door O-ring leaks are the most common failure.

Common defects

Smoke Event: Charge buildup in powder layer causes ejection: tune NeuBeam charge-neutralisation; reduce beam current during pre-sinter scan.

Porosity: Insufficient volumetric energy density: increase power or reduce scan speed.

Solidification Cracking: Too rapid cool-down in brittle alloys: extend controlled cooling ramp.

Recoater Streak: Partially fused powder blocks snag the rake: check powder flowability and bulk density.

What it is used for

Aerospace Ti-6Al-4V Structures: Zero residual stress and no post-build heat treatment save 1–2 days per build cycle.

Orthopaedic Implants: Hot-part process achieves osseointegration surface texture without additional HIP.

Novel Alloy R&D: Material-agnostic platform with Wayland custom parameter development for customer alloys.