Laser-assisted rapid prototyping

The rapid manufacture of prototypes is a decisive factor in accelerating the development process of new products. The techniques used for this purpose are summarized by the term rapid prototyping. The development of rapid prototyping machines is pushed forward worldwide. LZH has been participating in this international competition for more than ten years. However, LZH concentrates on developments in those areas where the precision of functional prototypes is most important.

In the field of 3D-laser cladding LZH focuses on precision components and their optimization with the aim to create highly precise weld seams that require no or only minor reworking. Figure 1 illustrates the basic principle of laser cladding. The laser beam generates a melt pool on the workpiece. Due to the rapid movement of the laser beam the melt pool cools down quickly and usually has an especially fine-grained metallic structure.

Figure 3 shows demonstrators that were created using 3D-laser cladding. These molds demonstrate how laser cladding enables the creation of any 3D-structure.

A large variety of metals can be processed using 3D-laser cladding. Titan, iron, nickel, cobalt and aluminum materials were already used at LZH. Theoretically, the maximum size of a 3D structure is only limited by the travel of the CNC system. The smallest line widths created at LZH using 3D-laser cladding with standard components are < 500 µm. Wider structures can easily be created.