Laser Systems for Additive Manufacturing

Laser Systems for Additive Manufacturing

Laser cladding and 3D metal printing tailored to your application

Additive Manufacturing

By providing hardware, software, laser sources and services Coherent is one of the few suppliers worldwide offering AM process solutions for both of the relevant laser technologies: Metal powder bed fusion (L-PBF) and the direct metal deposition (DMD) process. Both the DMD and laser L-PBF AM systems from Coherent are dedicated to metal materials offering an innovative and cost-effective approach for the manufacturing, repair or optimization of industrial components. With the establishment of a global Center of Excellence for Robotic & Additive Manufacturing the commitment to these disciplines both in terms of R&D and industrial collaboration only continues to increase and provides a distinct resource for Coherent clients and partners to push the boundaries of their AM applications.


3D Metal Printing (L-PBF)

Laser Powder Bed Fusion (L-PBF) 3D printing technology, perhaps the most familiar process for metal 3D printing, enables the manufacturing of a vast array of geometrically complex products within a controlled powder bed, where parts are built one layer at a time as the laser selectively melts the powder to the preceding layer, forming a solid part. The built-up component sizes are constrained by the size of the powder bed, but parts are produced to exacting levels of accuracy. A very wide range of industrial sectors, including but not limited to dental, medical, engineering, tool & mold making and advanced academic education & research already adopted this technology in their daily work.


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Dental Industry

3D printing is a game changer for the dental industry, with capabilities that permit the mass customization and production of dental prostheses. 3D metal printing technology is ideally suited for the on-demand production of customized implants, crowns, partials, abutments and bridges made of Titanium and CoCr within the digital dental workflow. Short processing times and an excellent ROI make this technology a perfect solution for dental laboratories.

For this application, we recommend the 3D metal printer: CREATOR Series


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Medical

The advantages of additive manufacturing for medical applications are well documented and cover a broad spectrum of disciplines for medical devices and surgical implants where customization and enhanced product functionality improve patient outcomes. With specific and approved materials within a certified process, the 3D metal printing is a capable and highly competitive technology for a range of medical applications. Examples are surgical instruments, complex mass and customized implants, as well as new medical device development and manufacture.

For this application, we recommend the 3D metal printer: CREATOR Series


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Engineering

3D metal printing is an alternative for turning- and millwork and is among others suitable for production in lower volumes, complex forms and precision parts. The technology enables tool-less prototyping of metal components and allows the creation of complex geometries with focus on weight reduction, operational optimization, direct digital manufacturing and a reduced use of raw materials and energy. Tooling can now be fabricated in a short time with minimal post-processing required, thereby reducing development costs while increasing speed to market.

For this application, we recommend the 3D metal printer: CREATOR Series


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Education & Research

Research and teaching of the L-PBF process, development of different materials and material combinations, re-thinking of construction - i.e. bionic structures - or development of different laser and printing strategies: L-PBF technology enables academic and research institutions to utilize advanced manufacturing techniques for specific research into processes and materials.

For this application, we recommend the 3D metal printer: CREATOR Series


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Tool & Mold Making

Additive manufacturing techniques are increasingly used as a solution for producing molds as well as tools quickly and cost effectively, avoiding the exorbitant costs of traditional tooling methods. Complex metal tools and molds can be created at a fraction of the cost for small and medium sized production runs. This speeds up the overall production process and can increase functional properties of the parts, whereby long delivery times and storage costs are reduced.

For this application we recommend the 3D metal printer: CREATOR Series

Wire cladding

Wire laser cladding is a coating method with excellent properties and high deposition rate and is used for the repair of components and functionalizing of surfaces. It is possible to apply material of the same type or to create functional layers according to the requirements for the coating. This process is particularly economical as the filler wire is constantly utilized to 100 % as the material supply is independent from gravity. Compared to the powder cladding procedure this process is very clean and both user and environmentally friendly. Current application fields range from repair of engines and turbines to coatings of functional surfaces on forms and tools up to direct additive manufacturing of metal components.


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Manual wire cladding

Laser cladding by wire is a manual process, where the welder looks through optics onto the object to be welded and places the filler metal manually onto the workpiece. In most cases, this filler metal consists of a thin wire with a diameter between 0.15 and 0.8 mm. For best results, the welder directly and instantly varies the welding direction and the quantity of the supplied filler metal. The quality of the cladding process is highly dependent of the used wire materials, the process parameters and the operator skills.

For this application, we recommend the cladding systems: Desktop, Select, Integral, Performance Family, EVO MOBILE, and LRS EVO

Powder Cladding

Laser cladding with a powder nozzle, also called direct metal deposition (DMD), is not only ideal for repairing and touching up workpieces. It has also already been creating a sensation in additive manufacturing for quite a while. Thanks to software-supported production options, it can be leveraged to completely automatically produce a vast range of geometries. Material can be deposited in a single- or in multiple-layers; even entirely new objects can be made and fused with existing components. In addition to faster throughput, exceptional quality, and low mingling of base and cladding powders, DMD excels with minimal dimensional distortion thanks to low heat penetration. These benefits, coupled with smooth, minimally porous surfaces, help to largely eliminate subsequent finishing steps. DMD thus also delivers major time and cost savings.


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Surface Coating and Wear Protection

DMD Technology enables tool and component protection against wear or corrosion by applying coatings with optimized surface properties preventively onto existing structures. The applied surface coatings provide extended service life contributing to cost reduction and uptime improvement. In particular heavy industries like oil & gas or vessel building DMD became very popular to protect coat drills, shafts, and gas turbine components.

For this application, we recommend the cladding systems: ROBOLASER, EVO MOBILE


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Repair & Modification

High-valued parts such as turbine engines, blades, housings, shafts or tool molds can be damaged due to their high operational requirements. DMD technology is an effective and cost-saving way to repair those components with even improved surface qualities or design changes, minimizes the downtime and less loss of production.

For this application, we recommend the cladding systems: ROBOLASER, EVO MOBILE, LRS EVO, EVO CUBE


automotive laser cutting

Additive Manufacturing

The coaxial configuration of the powder nozzle and laser lets material be deposited regardless of the substrate’s direction of movement, the workpiece size only depends on the freely scalable limitations of the axis system used for the manufacturing process. This provides nearly a maximum of design freedom even for very high-complex geometries, the workpiece can grow in any direction.

For this application, we recommend the cladding systems: ROBOLASER, EVO MOBILE, LRS EVO, EVO CUBE