Triples production efficiency in large-format metal 3D printing

Deep Blue Aerospace has reduced the time it takes to produce a rocket engine combustion chamber by approximately 70% thanks to Farsoon Technologies’ metal 3D printing technology. The companies have been cooperating with each other since 2022, when Deep Blue, operating in the aerospace industry, invested in a Farsoon FS621M 3D printer to use it in the production of rocket engines.

Farsoon and Deep Blue Aerospace worked together to deliver higher efficiency at reduced costs in the production of large part sizes exceeding 600 mm. The FS621M 3D printer has working dimensions of 620 x 620 x 1100 mm and was therefore considered a potential enabler of these goals. After months of testing and verification, Farsoon reported that it had achieved “a large number of successful implementations of machine and process optimization aimed at productivity and higher quality.”

These include 3D printing of a combustion chamber with a diameter of 600 mm and a height of 780 mm. After detailed analysis and optimization of the optical system, process parameters, scanning strategy and re-powder coating of the FS621M machine, the partners managed to produce the combustion chamber in 96.5 hours, instead of 327 hours.

With these advances made, Farsoon provided details on improvements made to the metal powder fusion process that helped reduce production times. The key to achieving this success, the company says, was the development of advanced multi-laser scanning strategies and a fast-acting algorithm in overlapping areas, which helped overcome challenges related to laser power control, galvo system calibration, overlap consistency and multi-laser support. task coordination. Advanced scanning strategies improved scanner and galvo control with optimized parameters, improving communication efficiency by 39% while ensuring internal metallurgical quality.

Meanwhile, Farsoon also worked on improving the gas flow design to enable timely smoke removal and smoother operation of multiple lasers, and the control system was optimized to reduce waiting times between lasers and minimize downtime. The company then made “meticulous adjustments” to processing parameters to help achieve high-quality surfaces.


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