Raise3D launched the new Raise3D MetalFuse system, an end-to-end fully integrated in-house ecosystem for metal 3D printing, developed in close collaboration with BASF Forward AM and using Ultrafuse Metal Filaments. The main applications of metal parts produced with FFF 3D printing are tooling, jigs and fixtures, functional parts and prototypes, and small-batch production.
Raise3D MetalFuse system is comprised of the desktop metal 3D printer Forge1, the catalytic debinding furnace D200-E, the sintering furnace S200-C, the slicer ideaMaker Metal, and uses Ultrafuse Metal Filaments from BASF Forward AM. ideaMaker Metal is a modified version of ideaMaker optimized for the use of Ultrafuse Metal Filaments, with unique features, provide the required part density and repeatability to create end parts of the highest quality.
The sinter D200-E uses an oxalic acid catalytic debinding process, traditionally used by MIM technology, which is safe and environmentally friendly. According to Raise3D’s internal analysis, excluding parts with a very simple design, the Raise3D MetalFuse solution produces parts with better quality and a lower cost, particularly for small batches, than AM metal laser sintering solutions in the market.
FFF technology allows for full design freedom, which makes possible the production of complex parts that would otherwise be too expensive, or could not be produced, with MIM. This additional design freedom can also allow better mechanical properties of the end parts, which may translate to having FFF as the most cost-efficient technology for metal parts production, even for medium or large batches.
Raise3D MetalFuse is the first AM metal end-to-end solution using an oxalic acid catalytic debinding method; other AM metal parts production use solvent and thermal debinding. Oxalic acid catalytic debinding is a safe and environmentally friendly process. In addition, according to Raise3D’s internal testing, debinding with a catalytic method allows for a reduction of 60% in the debinding time, an increase of the part’s density to up to 98% of wrought iron’s density, and an increase of up to 52% of yield strength when compared to the solvent method.
AM metal printing solutions Raise3D MetalFuse production is safer as it uses filament as a consumable, which makes its handling totally safe and extremely easy; this differs from the dangerous and difficult material handling of metal powder-based solutions, like the ones currently on the market. Raise3D MetalFuse-produced parts with Ultrafuse Metal Filaments are in general 1.4 to 2 times cheaper than most metal powders; also, the solution requires less investment in hardware.
Firat Hizal, Head of Metal Systems Business Group at BASF 3D Printing Solutions said: “Metal FFF offers a great advantage to the customers; it is affordable, easy to use and eliminates a very complex step in comparison to other Metal AM techniques like powder handling. According to Hizal, “MIM technology can be the best solution to manufacture parts in large volumes, whereas Metal FFF can be used to produce more sophisticated designs in small and medium-sized batches. We are very impressed by the capabilities of the MetalFuse ecosystem and convinced that Raise3D MetalFuse together with our Ultrafuse Metal Filaments, will deliver excellent value to customers. We are installing our first Raise3D MetalFuse unit in our facilities in Shanghai soon. We will continue working closely with Raise3D to further optimize the MetalFuse ecosystem”.
Raise3D MetalFuse is the first complete in-house solution optimized for Ultrafuse Metal Filaments. Besides the benefits resulting from the great properties of these filaments, being a complete in-house solution has the additional advantages of speed, by avoiding the need to interact with third parties, substantial time can be saved,
making it possible to go from the initial “idea” to the “final part” in a couple of days, minimizing the handling of the ‘green parts’ and ensuring full confidentiality, by having the full process in-house, as opposed to when the debinding and sintering need to be done externally.
Edward Feng, Global CEO of Raise3D 3D, said: “The collaboration with BASF Forward AM is a milestone in Raise3D’s history, and a solid step towards our vision of offering a perfect ecosystem to facilitate Flexible Manufacturing. Our Raise3D MetalFuse system combined with Ultrafuse Metal Filaments from BASF Forward AM offers a solution to additive manufacturing of metal parts that are easier, safer, cleaner, cheaper, and faster, than the current AM metal parts productions, making it accessible to everyone using those solutions. In many cases, we have also confirmed that Raise3D MetalFuse can be competitive with MIM, which makes us confident that MetalFuse can represent a breakthrough in metal parts production”.
Raise3D will start the worldwide large-scale delivery of Raise3D MetalFuse commercial systems from the first half of 2022, through select sales partners. Forge1 will also be made available for customers who already have in-house debinding and sintering capacity. Prices of the Raise3D MetalFuse system are not disclosed at this time, but Raise3D asserts that, in addition to all mentioned technical advantages, it will have a substantially lower total cost of ownership than the solutions available in the market.