Wayland Additive’s Calibur3 for Geometrically Complex Metal Parts

Wayland Additive’s Calibur3 metal Additive Manufacturing (AM) system is said to enable the manufacture of geometrically complex, fully dense, high-quality parts in a wide variety of difficult-to-process metals. 

The system features the NeuBeam hot part process rather than a hot bed process, which means it can efficiently create parts that are free of residual stresses because the high temperatures are only applied to the part and not the bed. It enables the production of larger parts without having to worry about residual stress or gas cross flow and without having to pre-sinter the powder bed.

The company says the system can replace traditional manufacturing methods, especially for high-wear parts and components in the aerospace, medical, energy and power generation, motorsport and automotive, mining and mineral extraction, and military and defence sectors. 

According to the company, the most fundamental issue with eBeam AM technology has always been the unstable nature of the process. Wayland says it has resolved this with the fully neutralized NeuBeam process. “Not only does it overcome many of the problems associated with traditional eBeam processes but it offers a complete and well-thought-out solution,” says Peter Hansford, business development director at Wayland Additive. “This includes the design of the machine, its modularity and user interface, ease-of-use, and the fact that a depowdering and recycling (DPR) station is all included in the Calibur3 package.”

The company says the system features in-process monitoring, open parameter access, large build volume and an advanced powder management/dispersal system. It also offers an original melt strategy with multiple meltpools from a single source. The system comes with easy machine calibration and excellent cooling control, with the ability to control cooldown rates. It has an eBeam column with higher usable power, longer source lifetime and wider deflection. Also, the system is said to ensure that customers have an end-to-end solution with no need to consider purchasing ancillaries for postprocessing and more.