HP Debuts Metal Jet S100 for Mass Metal-AM Part Production

September 12, 2022
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HP-S100-Metal-Jet-IMTSAt IMTS 2022 booth 433000, HP debuted its Metal Jet S100 binder jetting system, touting its capability for mass production of metal additive manufacturing (AM) parts and announcing its commercial availability. Currently the HP Metal Jet S100 utilizes two stainless-steel powders—HP Metal Jet SS 316L and HP Metal Jet SS 17-4PH—with process parameters that achieve MPIF 35 properties. Other materials have been evaluated and can be developed for specific applications and properties, according to HP officials.

The S100 features a 430 by 309 by 200-mm build volume, with binder jet layer thicknesses ranging from 35 to 140 μm. The two-printbar printhead system boasts 63,360 nozzles to provide four-times print redundancy at 1200-dpi resolution, with automatic nozzle health detection. The S100 can provide build speed to 1990 cm3/hr.

In practice, the S100 works like this: Before printing, its powder-management station automatically blends, sieves and loads metal powder into the build unit according to the user-defined print job and customized parameters. After completion of printing and curing, the build unit is manually inserted into the S100’s powder-removal station, which automates the removal and recovery of loose powder for 100-percent reusability, while simultaneously performing build-unit cleaning. For any fine powder remaining on printed parts, the powder-removal station includes separate vacuum attachments for manual removal of the fine powder. All reclaimed powder is pneumatically recovered into the powder-management station’s portable tank for storage, and then reintroduced into the powder-management station. The modular makeup of the S100 enables build units to travel between four different stations, allowing users to run production continuously at scale for mass metal-part production.  

Available software for the S100 through HP Metal Jet Software Solutions includes HP Metal Jet Command Center, a client/server application for system setup, registration, device monitoring and connectivity management; HP Metal Jet API, an application programming interface for streamlined access to device data and device orchestration for process development and production workflow management; and the HP Metal Jet Process Development Suite, that provides integrated build management, process-parameter editing, sintering simulation and process monitoring to reduce time and effort in process development.

And, HP Metal Jet Solution Services provides a comprehensive suite of onboarding, maintenance and professional services. Professional services include optimizing and accelerating users’ application designs as well as efforts to develop user processes and new materials.

Post-printing, HP can help with sintering-operation requirements. HP recommends parameters for each qualified material, or can aid in developing these parameters. And, for additional finishing beyond sintering, HP’s engineering team provides services to assist in achieving final-part properties via processes such as machining, polishing, coating and hot isostatic pressing.

“Since announcing the breakthrough Metal Jet technology in 2018, we have been working to develop the industry’s most advanced commercial solution for 3D metals mass production,” says Ramon Pastor, HP Inc. global head and general manager of 3D metals. “3D-printed metal parts are a key driving force behind digital transformation, and the new Metal Jet S100 solution provides a world-class metals offering for our customers, from the first designs right through to production, but, more importantly, helps them to realize the unlimited potential for digital manufacturing.”  

HP-S100-Schenider-Electric-IMTS-breakerHP metal-AM partners and customers include GKN, Parmatech, Cobra Golf, Legor Group and Volkswagen, with the company reportedly also collaborating on mass metal-part production opportunities with Domin Digital Motion, an industrial company focused on hydraulic systems and valves; Lumenium, a startup developer of advanced rotational engines; and Schneider Electric.

Working with GKN, a new filter used on Schneider Electric’s NSX breaker was produced using HP Metal Jet technology, which could not be achieved with conventional industrial manufacturing capabilities due to the component’s shape and material complexity, according to Schneider Electric officials. The binder jetting technology reportedly facilitated design of new power-filter shapes that reduce gas, pressure and heat impact in a more limited space, and also resulted in significant productivity gains and environmental benefits.

“We are excited about the new possibilities for our business as a result of this collaboration with HP,” says Michael Lotfy, Schneider Electric senior vice president of power products and systems-North America. “Leveraging HP Metal Jet, our teams have delivered a proven use case showcasing the benefits of digital manufacturing and 3D printing, and we look forward to uncovering many more applications that meet the evolving demands from our customers addressing the challenges around sustainability and Electricity 4.0.”

Says Didier Deltort, president of HP’s personalization and 3D printing business: “We are witnessing entire industries, from industrial to consumer, and healthcare to automotive, looking to digitally transform their manufacturing processes and supply chains in a world where volatility is the new normal. The introduction of our new Metal Jet commercial solution, along with innovative collaboration with market leaders such as Schneider Electric, is delivering the blueprint for more sustainable, reliable and efficient manufacturing.”

Industry-Related Terms: Case, Center, Layer, Polishing, Run, Scale
View Glossary of Metalforming Terms

 

See also: HP Inc., GKN Sinter Metals Engineering GmbH

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