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After making significant strides towards the ability to manufacture larger parts, Chinese company Bright Laser Technologies (BLT) has introduced a high-precision metal LPBF (laser powder bed fusion) technology. This marks a major leap in micro-part manufacturing for the company, addressing long-standing challenges of surface finish and accuracy that have plagued traditional metal LPBF methods. The impact of this technology is far-reaching, and is expected to transform a variety of industries that rely on the production of complex, precision parts.
New high-precision metal LPBF
Traditional metal LPBF techniques have been the basis for additive manufacturing, but they often fall short when it comes to producing small parts with high surface quality and precision. Surface roughness and dimensional accuracy are particular areas of concern, limiting the application of this technology in areas where stringent standards are required.
Only one other company, 3DMicroprint, has made significant progress in this direction, producing incredible ultra-precise parts, but progress has been slow in terms of market adoption.
BLT's precision metal LPBF technology addresses these issues by refining the laser fusion process and optimizing material deposition. In this way, BLT has achieved significant improvements in surface roughness and accuracy. The new method can produce parts with surface roughness as low as Ra 2-3 μm and dimensional accuracy of less than 0.05 mm. This level of precision opens new possibilities for the production of parts that require high detail and smooth finishes, such as those used in medical devices, aerospace and advanced engineering.
F-RD topology structure model
A key highlight of BLT's innovation is the development of the F-RD topological structure model, a sophisticated design that showcases the potential of the company's new technology. The F-RD model is based on an algorithmic digital design approach, creating periodic minimal surfaces with complex curvature variations. The design not only demonstrates the advanced capabilities of BLT's metal LPBF technology, but also highlights the improved surface texture quality that can be achieved compared to traditional methods.
The F-RD model serves as a proof of concept, demonstrating how digital design and advanced manufacturing techniques can be combined to create structures that were previously impossible to produce with such precision and quality. The model is a testament to the potential of BLT's technology to push the boundaries of what is possible in additive manufacturing.
Practical application of BLT technology
BLT's high-precision metal LPBF technology has already proven its value in several real-world applications. In the medical industry, where precision and quality are paramount, BLT has successfully manufactured miniature medical parts with complex internal channels that meet strict quality standards. The parts' high precision and excellent surface finish highlight the technology's suitability for manufacturing critical components in the medical sector.
As another example, BLT worked with the MicroNeuro project to develop advanced structural parts, demonstrating the efficiency and effectiveness of BLT's techniques to design complex parts while reducing development time, improving material utilization, and minimizing waste.
A particularly challenging application was the production of a stainless steel threaded part with a minimum thickness of just 0.1 mm. BLT's technology achieved this without the need for support structures, and the surface roughness of the final part was Ra≤1.6 μm. This case highlights the precision and ability of the technology to manufacture complex, high-quality components that meet demanding specifications.
BLT is committed to continuous research and innovation with the goal of expanding the application scenarios of metal LPBF technology to a wide range of industries. From aerospace to biomedical engineering, the potential uses of this technology range from small to large.
