Service and consulting - simulation, construction, and prototyping in the area of additive manufacturing

Heraeus stands for years of experience in metals production and processing. In addition to our expertise in additive manufacturing, we offer you everything from a single source so you can successfully produce functional components.

At Heraeus you get not only high-quality, consistent metal powders, but also the appropriate printing parameters for your particular component. Furthermore, we offer assistance in optimizing your design for additive manufacturing, small batch production (laser beam melting or electron beam melting), as well as recycling of excess metal powder. In addition to these services, we offer simulations of various process steps before we print, for the purpose of optimizing your print results.

Simulation

Simulation

In simulations, we have expertise between topology optimization, construction simulation, powder bed simulation, and process simulation.

Topology simulation results in savings on materials, weight reduction, and efficiency, and meets all the necessary requirements that have been set for the component.

In the construction simulation, we determine the optimal orientation of the component in the printing process, and also the necessary support structures and support structure strengths. In this way, we reduce possible deformations, post-processing expenses, and production costs by optimizing the construction time and material usage.

We use powder bed simulation to determine how to spread the fresh powder onto the powder bed as homogeneously as possible. In addition to powder characteristics, process parameters such as the shape and speed of the blade or roller have an influence on undesired separation of the powder particles according to size.

The process simulation simulates the actual manufacturing process. Laser speed, laser energy, and laser track are coordinated in virtual test runs so that a component is formed with the best quality and density, in accordance with your requirements. This drastically reduces the number of test prints that are necessary before the optimal component is manufactured. Development and material costs are significantly reduced.

Construction assistance

Construction assistance

Design freedom is a significant advantage of additive manufacturing. However, the specific design rules for 3D printing, which differ depending on the material, must be taken into account. For that reason, we assist you in designing your component by providing specially trained designers and topology simulation.

With intelligent design, it is possible to reduce weight while maintaining the same component strengths, and post-processing steps can be reduced. An advantage that pays for itself.

Printing parameters

Printing parameters

Metal powder and printing parameters need to be customized for every printer, otherwise there is a risk that your component will not possess the desired properties. In extreme cases, even printers from the same manufacturer and series can lead to different printing results. We will help you achieve reliable reproducibility in additive manufacturing. Job after job!

Printer

Printer

Metal powder and printing parameters need to be customized for every printer, otherwise there is a risk that your component will not possess the desired properties. In extreme cases, even printers from the same manufacturer and series can lead to different printing results. We will help you achieve reliable reproducibility in additive manufacturing. Job after job!

Prototypes

Prototypes

Before you start production we can use simulation to check whether your components are suitable for additive manufacturing. We use our own equipment (laser beam melting or electron beam melting) for this purpose. We prepare samples and prototypes and produce small batches for you, all in accordance with the motto: reduce costs, increase quality.

Post-processing (hot isostatic pressing and heat treatment)

Post-processing (hot isostatic pressing and heat treatment)

The quality of our powders can reduce the amount of surface post-processing that is necessary. If post-processing with hot isostatic pressing is necessary, we can use our own equipment without any delays. You get everything from one source and save time.

Reconditioning

Reconditioning

In the interest of consistent print quality, surplus powder cannot be reused ad infinitum. However, leftover powder, support structures, and misprints do have considerable material value, depending on the metal. With our background of many years of expertise in processing metals, we will organize a complete and documented powder cycle for you, which will make costly disposal unnecessary.