Hybrid Manufacturing with SigmaTau Robot: 3DMD Process combined with Machining of Large Parts

What is the 3DMD Process?

Dynamic Material Deposition (3DMD) combines powder-based laser deposition welding with Additive Manufacturing of metallic components. In this process, a laser melts the material which is then deposited onto a substrate. This method speeds up production, decreases energy consumption, and minimizes warping.

The Challenge of Size in Additive Manufacturing

Additive Manufacturing has a notable limitation: while it produces small parts with high precision, large components often lack detail and quality. The hybrid SigmaTau equipped with a DED (Directed Energy Deposition) or a 3DMD process addresses this issue, enabling economical production of large components without sacrificing precision.

Versatility and Applications of 3DMD

Originally, the 3DMD process was primarily used for coating components. However, its capability to process various alloys and metals through a nozzle-based powder supply makes it extremely versatile. Applications include:

Protective coatings that extend the lifespan of components
Specialized surface treatments
Reinforcement features for lightweight construction, leading to material cost savings
Repair of components, as well as traditional Additive Manufacturing

Machine Specifications for Optimal 3DMD Performanace

The implementation of the 3DMD process demands machinery that can achieve both rapid operations and meticulous precision, requiring strong stiffness and dynamic capabilities. The SigmaTau robot's design enables high surface rates of up to 1,000 cm²/min and build rates of up to 600 cm³/h. It is specifically engineered to maintain speed in all directions and reorientations to keep as close to net shape as possible, supporting efficient production.

Precision Manufacturing of large parts: The Integration of 3DMD in the Hybrid SigmaTau Robot

Cognibotics, together with machine builder ELHA-MASCHINENBAU and technology partner Ponticon, has successfully integrated the Dynamic Material Deposition (3DMD) process into the hybrid SigmaTau robot. This collaboration has crafted a versatile system capable of handling the manufacturing and post-processing of intricate components crafted from a variety of alloys and elementary metals.

The hybrid SigmaTau robot handles both the manufacturing and post-processing of intricate parts made from various alloys and metals within a single setup. This includes:
- Additive manufacturing
- Coating
- Reparation
- Post-processing and machining in the same setup
Large-Area Production: Supports the fabrication of large-area components within a work envelope up to 3 x 2 meters in the Y x Z dimensions, with an extensive range in the X dimension, ensuring precise outcomes and near net-shape structures.
Exceptional Dynamics: Achieves maximum accelerations of 2.5 G, significantly enhancing manufacturing speed and operational capabilities.
Microstructure Fabrication: Produces 3D microstructures with a minimum wall thickness of 500 μm and a surface roughness of approximately 20 μm.

Mobile Hybrid Manufacturing

Furthermore, Cognibotics has engineered the SigmaTau HD to fit inside a standard 40-foot container, providing a workspace measuring 1.2x1.2x2.5 meters. This design facilitates easy transportation and supports additive manufacturing and machining operations within a single setup. It offers the versatility to handle both production and repairs, whether in-house or on-site. Additionally, an advanced calibration system quickly restores precision after transportation, maintaining consistent accuracy in any environment.