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BFW-m2nxt presents new PHOTON 4000G metal DED system

The game-changing giant, dual head system is proudly made in India and priced at €1.9 million

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Bharat Fritz Werner Ltd (BFW) and m2nxt (a BFW subsidiary), India’s leading CNC and Industry 4.0 machines and solutions companies, launched the PHOTON 4000G Laser-DED machine, made in India and available worldwide in 2023.

BFW specializes in advanced manufacturing technology platforms, with more than 50,000 machines and systems installed worldwide. To address changing industry needs and the opportunity for cost-effective and large format metal additive manufacturing, specifically in the laser-powder & laser-wire directed energy deposition (DED) segment, BFW and its subsidiary m2nxt first entered the DED metal AM industry in September 2021, establishing a technology-driven global team to drive this business.

The company’s 60 years of expertise in machine tools gives it the capability and infrastructure to develop and manufacture the world’s largest, fastest, and lowest price L-DED machine to exact specifications and reliability. BFW also prides itself in its capability, commitment, and track record to provide world-class customer support for installation, commissioning, training, and expert consultancy to any customer worldwide.

Available January 2023

The PHOTON 4000G, the first system launched by BFW and m2nxt, will be available from January 2023. This system offers a 36 cubic m hermetically sealed Argon Chamber (33% larger than any other commercial AM system) and a 10.4 cubic m part build envelope (200% larger than any other inert chamber commercial AM system). It also offers other features such as dual-deposition heads on dual ram gantry – for powder & wire deposition along with  an industry-first standard spec 6KW fibre laser with a beam splitter to direct variable power to both heads

Other standard features include the 3m x 3m x 4m argon chamber with a stainless steel interior, multiple laser safe viewports & glove ports, full-size front & rear doors, motorized parts table, heavy-duty tilt/rotate the table, real-time process monitoring via pyrometry/thermography/machine vision, full 5-axis control/build software, ID cladding head with 2m length, and much more, making it a game-changer in the DED industry.

BFW and m2nxt present new PHOTON 4000G metal DED dual head system, priced at €1,9M, and proudly made in India

Best cost per cubic meter of part ratio

BFW has confirmed a starting MSRP of €1,990,000, which translates to €190,000 per cubic meter of part build volume: that’s 2.5x to 20x lower than other common L-DED machines currently on the market. Printing large/huge parts in the PHOTON 4000G will thus be significantly more economical than other L-DED argon chamber machines. This economic business cases bring game-changing opportunities, competitive advantages, and technical capability to potential users for printing large/very large metal alloy components. specialising in freeform fabrication, hybrid manufacturing and repair applications for the aerospace, defence, oil and gas, power, mining, and heavy industries.

BFW intends to install Photon 4000G machines in its Dr. Abdul Kalam Centre of Excellence in Bangalore for contract manufacturing, as well as effectively market & support the machine in India and globally. “I have applied and marketed the most premium DED equipment in the industry over the past 20 years,” stated DED industry veteran Ashok H. Varma, EVP & Global Leader, Additive Manufacturing at BFW. “I talked to hundreds of potential & existing industrial users and identified a large global opportunity to satisfy a glaring unmet need – the significant gap between demand and availability of truly industrial-grade yet affordable L-DED systems and the practical experience required to ensure good results and economic viability. I have contract-printed parts priced at more than $250,000, and the BFW Photon 4000G can print similar parts at less than half that cost once amortization and operational costs are considered. It is also evident that the new wave of metal AM industrial manufacturing will be driven by Laser-DED

“Most currently installed systems are in laboratories or light industrial applications, many are “Do It Yourself systems”, many are underpowered, undersized, or overpriced systems, many are idle or under-utilised, with few suppliers and users having the practical experience to optimally utilise this technology and reduce ‘time to value’. We believe we at BFW will be instrumental in closing the gap between supply and demand of large, very large, and huge 3D printed parts using laser-powder and laser-wire metal deposition, for free form fabrication and fine/heavy cladding/repairs.” added Varma.

More Photons on the way

“BFW and m2nxt have introduced market disruptive high technology products for the last six decades. PHOTON 4000G is one more such product which will not only bring technology differentiators but would be the First IoT enabled Smart AM machine” contributed Ravi Raghavan, MD BFW.

The fact that this world-leading metal AM machine is being manufactured entirely in India is a testament to the Indian Government’s “Make in India” initiative and will address significant, critical and strategic applications in the Defence/Space/Aerospace/Heavy Industries segment. BFW will soon announce the rollout of several other Photon machine models including Photon 2500 and Photon 1000 series, with gantry and robot, mobile systems for in-situ repair/manufacturing and hybrid AM configurations.

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