On July 15, 2019, the U.S. Army Research Laboratory (ARL) 's Combat Capability Development Command and the US 3D printer manufacturer 3D Systems signed a $ 15 million machine development contract. Working with the National Manufacturing Science Center (NCMS), 3D Systems' mission is to create "the world's largest, fastest, and most accurate metal 3D printer." Once installed in the Army, the technology will be used in leading aerospace and defense.
Dr. Joseph South, ARL's next-generation additive manufacturing project manager, commented: "The Army has enhanced capabilities by strengthening relationships and interoperability with commercial partners. So far, powder bed laser 3D printers are too small, too slow, and too inefficient Accurate, unable to mass produce major ground combat subsystems, "
The 3D Systems metal 3D printer series currently consists of seven machines, each using the company's PBF direct metal printing (DMP) technology. The largest machine in this series is the DMP Factory 350, which has a maximum build capacity of 275 x 275 x 380 mm (width x depth x height). The 3D printer required by ARL has a construction size of 1000mm x 1000mm x 600mm, which can build parts that are 3 feet in length and depth and less than 2 feet in height. At this scale, ARL's 3D printer exceeds the size of the largest machines currently on the market, such as SLM Solutions SLM 800 (500 x 280 x 850 mm, L x W x H) and GE Additive's Beta project ATLAS (950mm x 810mm) × 300mm, X × Y × Z).
It will be developed by 3D Systems and NCMS as part of the Advanced Manufacturing, Materials and Processes (AMMP) program that opened in October 2018. NCMS President and CEO Lisa Strama commented, "As a key project of the AMMP program, [this project] will bring major breakthroughs to our members and partners, increase efficiency and accelerate innovation into the market."
Other specifications include a minimum wall thickness of 100 μm and a minimum layer thickness of 30 μm.
According to the US Army's Additive Manufacturing Implementation Plan, the unit has been exploring many 3D printing projects for the past 20 years.
ARL is also working to develop stronger materials for additive manufacturing. On July 15, 2019, AMMP will submit a submission on "Additive Manufacturing of Next Generation High Strength Aluminum Alloys".
With a large metal 3D printer project, the military hopes to achieve more efficient design and production of durable parts and accelerate product applications. It will focus on the production of the Army's critical supply chain, including parts related to long-range ammunition, next-generation combat vehicles, helicopters, and air and missile defense capabilities. Chuck Hull, co-founder and CTO of 3D Systems, commented: "Through this collaboration, we look forward to providing a unique manufacturing system. ARL has begun to transform its operations with the power of additive manufacturing, and we look forward to working with They have further collaborated to enhance manufacturing capabilities by providing new processes, materials and technologies. "