Improving utilization and expanding gear steel availability, exceptionally high heat-resistant or high-strength specialty steels may become more attractive for high-strength gear applications.
FREMONT, CA: Additive manufacturing (AM) is a rapidly changing industry. It is essential to focus on two areas—large-format metal AM technologies and binder jetting—and examine new industry entrants and relevant adjacent suppliers like powder makers, material designers, and surface finishing technology providers. For instance, the AGMA Emerging Technologies Committee (ETC) conducted a Rapid + TCT Exhibition show floor tour (Rapid). For several years, the ETC's 3D Printing Sub-Committee (3DPC) has monitored the additive manufacturing (AM) industry and provided AGMA members with condensed industry updates via webinars, white papers, and other news updates.
Polymer or plastic AM for tooling, jigs, and fixtures establish applications that may help gear makers, gear users, and adjacent gear manufacturing suppliers. Despite general availability for non-AM powder metal applications, AM standard gear alloy is scarce. Printing resolution limitations require machining for precision gear applications. Printing was more expensive than traditional manufacturing, except for small-batch specific cases. Parameter optimization, in-process monitoring, and post-print inspection added expenses and barriers to gear application acceptance. Large-format metal AM methods, including directed energy deposition (DED), cold spray, and friction stir welding "interesting" for gearing repair.
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Low-volume replacement parts are hard to get. Large-scale gearing is expensive due to material requirements and restricted supplier options—a gear repair option for severely damaged giant gears that require material addition. Binder jetting is the "fastest" and "lowest cost" metal AM technology. Because of sintering problems and lower material characteristics than wrought or forged materials, the gear sector has not used the technology much. Businesses' improvements in productivity, part quality, and alloy range supported the 3DPC's earlier finding that AM was not ready to impact gear manufacture strongly.
The dedication to serial manufacturing as a machine builder and user of the technology gave it a decisive view of AM's potential for high-volume applications. It offers industry-leading deposition speeds and build-bed volume flexibility for multi-part batches and nesting. Sintering issues with more significant parts limit part size in both scenarios, although this is true for most binder jetting applications, not only 3DEO or Desktop Metal. Binder jetting can get used for non-high speed or high-load applications with medium- to high-volume demand. Binder jetting is not likely to be a favored alternative for most high-load gear applications due to its lower density, but it should see an increase in MIM and related powdered metal gears.
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