e¯MELT®-iM

Industrial 3D printer setting the industry standard for serial production

e¯MELT®-iM is a game-changer for industrial 3D printing, achieving higher productivity with open source accessibility in a robust, industrial package. This transformative system enables a more efficient, reliable, and cost-effective approach to serial production with 3D printing than previously possible.

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Features

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Open source system & OEM agnostic interfaces

Embrace the freedom to choose and integrate. e¯MELT®-iM is an open-source system that seamlessly interfaces with various production systems, including MES, providing unmatched flexibility in your production processes. This compatibility empowers you to adapt and evolve your manufacturing setup as your needs change.

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Fleet management

Realize the full potential of digital manufacturing with fleet management capabilities. Streamline your production lines, monitor processes in real-time, and gain valuable insights into your operations. e¯MELT®-iM helps you optimize efficiency and minimize downtime for maximum productivity.

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Modular & independent build units

Maximize productivity with e¯MELT®-iM’s independent, roaming build modules. This modularity allows for unparalleled flexibility and efficiency in production. By providing a dedicated area for turnaround operations, separate from the production line, the entire workflow is streamlined for enhanced ergonomics and safety. This allows for maximizing beam-on time for increased productivity.

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Outstanding heat management

e-MELT®-iM’s advanced heat management delivers exceptional quality and productivity through the combined power of ProHeat® indirect preheating, Pixelmelt® precision spot melting, and efficient build cooling. These features work together to significantly enhance efficiency, enabling you to meet demanding production schedules with ease.

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Sequential micro casting

e¯MELT®-iM employs sequential micro casting, our unique approach that combines spot melting with layer-wise powder bed fusion. This method delivers exceptional accuracy, detail, and material efficiency for consistent, high-quality results.

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Superior electron gun design

The e¯MELT®-iM features a state-of-the-art electron gun that combines high power with consistent beam quality, a critical component for maximizing productivity and achieving exceptional quality without compromise.

e¯MELT®-iM

Core technology

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Achieve faster processing with a diode electron gun that delivers a small electron beam spot size at maximum power output. This enables high-precision melting and accelerates production compared to traditional solutions.

The diode electron gun in e¯MELT®-iM is a key enabler to achieve faster processing compared to traditional solutions.

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Simplified cathode heating with a laser ensures stable operation of the electron beam generation unit. This robust design contributes to the overall reliability and longevity of the system.

By using a backside laser heating of the cathode e¯MELT®-iM enables a very high electron beam power with optimized spot size for 3D printing in powder in a stable, robust design for high-volume manufacturing.

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Precisely control material quality in complex parts with spot melting. This technique is ideal for developing and implementing new materials and achieving intricate geometries.

Electron beam technology can reposition the electron beam extremely fast compared to laser beam technology.

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A specialized cooling system for the build tank enables fast processing, especially beneficial for small build volumes. This efficient cooling allows for high build temperatures, expanding the range of materials and applications.

By using build tank cooling e¯MELT®-iM allows a high build temperature of 1000oC and higher.

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Powder bed heating in a secondary way by using a heat plate when easily chargeable powder is used as raw material in the manufacturing process.

Freemelt implements ProHeat®, a retractable plate heated by the electron beam to radiate heat onto the powder bed for powder sintering. This method, which avoids direct electron beam heating, prevents powder lifting and charging effects – a significant advantage when processing challenging materials in industrial manufacturing.

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Manufacturing surveillance for quality assurance using secondary electron detection. 

Electron backscatter detection provides high-resolution images of the powder bed and built parts, layer by layer, throughout the build process. This technology enables real-time process surveillance and quality assurance through electron detection.

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Build tank removal and replacement for fast manufacturing batch turnaround in e¯MELT®-iM

The e¯MELT®-iM system features exchangeable and independent build modules, allowing for quick exchange and versatile system placement within the factory. Once a build is complete, the module can be moved to a dedicated area for powder handling, part removal, and preparation for the next build. This streamlines workflows, minimizes downtime, and increases productivity.

Electron Beam Control

e¯MELT®-iM utilizes multiple coil technology for precise and dynamic electron beam control. This system, with individually controlled coil windings, generates a complex magnetic field that can be finely tuned for optimal beam shaping and focusing. This results in:

  • High Accuracy: Precise beam control ensures accurate build geometry and high-quality parts.

 

  • Fast Processing: Dynamic beam adjustments enable rapid melting and solidification for increased build speed.

 

  • Simplified Calibration: Individual coil calibration allows for easy adjustments and maintenance.

 

  • Enhanced Beam Shaping: Advanced correction fields further refine beam shape for optimal performance.

 

  • Software Upgrades: Improved functionality can be implemented through software updates, enhancing system capabilities without hardware modifications.

Technical data

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Beam power

Variable 0-6 kW

Beam acceleration voltage

60 kV

Build envelope

Ø 100 x H 325 mm

Process vacuum level

10-5 hPa (mbar)

Build sensorics

Backscattered electron detector, Pyrometer, NIR camera

Build module docking to beam on

20 minutes

Non gravity powder feed

Push piston

Spot size (min, FWHP)

200 μm

Operating system

Linux

Build file format

Open Build File (OBF)

Process variables

Real time

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