3D Printing ProcessesHigh Speed 3D PrintingMass ProductionMetal Additive Manufacturing

Get ready for Seurat’s Area Printing, a multi-laser, high-speed metal PBF process inspired by NIF

A new metal 3D printing process for large, true net-shape parts production

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Like CERN, ITER, the ISS and Nasa’s rovers, NIF (National Ignition Facility) is a wonder of engineering and one of the largest and most complex machines created by humans. Its purpose is to ignite nuclear fusion, making it produce more energy than it consumes, using multiple high-power lasers. Like all the other machines mentioned, it is unique and highly complex so it makes sense that it uses AM for some of its parts. However what is of particular interest in this specific case is that AM was not able to meet the size and resolution requirements for certain, otherwise unweldable, parts: and that this has inspired an entirely new high-speed, multi-laser AM technology called Area Printing, which the startup Seurat is now ready to market.

Seurat’s Co-founder and CEO James DeMuth just published on Medium the story of how the company and the technology have come to be. Inspired not only by the NIF’s requirements but also, as the name implies, by art, as Georges Seurat was the post-impressionist painter who studied the science of light.

You should read the whole story, which is amazing, however, the main point that emerges is that he began looking at AM while, working at NIF, he identified laser PBF as the only process capable of producing parts using an otherwise unweldable steel-nanoparticle composite material, which was the only material capable of withstanding the Sun-like temperatures (600°C – 1100°F) generated inside the NIF main fusion chamber.

Seurat
An early demonstration of DiAM wide-area photolithographic printing of metal layers using an optically-addressable light valve. For each build (impeller and LLNL logo) successive layers were built using a stitching approach which allowed additional efficiency to be achieved. Alternatively, scaling up the overall dimension can be achieved by simply adding diodes and expanding optics, up to the energy limit of the Q-switched system (2 J).

Part of the Lawrence Livermore National Lab (LLNL), the NIF houses 192 of the world’s most energetic lasers, all targeted at a single point. Just to put things into context, the lasers generate more energy in twenty billionths of a second than the entire US uses at any point in time. The problem is that to manufacture the entire chamber using laser PBF would take 200 years! Which is why – ultimately – along with co-inventors Bassem El-Dasher, Andy Bayramian, Joe Farmer and Sharon Torres, DeMuth began looking at a way to make PBF much faster without sacrificing resolution: this technology, which was co-developed with LLNL, now exists as Area Printing.

To be entirely fair, the technology sounds very similar to EOS’s announced LaserProFusion, which is also diode-based. Here it is applied to metals, which undoubtedly present a number of additional challenges compared to plastics. Based on LLNL’s Optically Addressed Light Valve (OALV), Area Printing works by patterning a laser beam with high-resolution images which can be programmed to block or let light through each of its pixels. This means that every pixel defines its own laser spot, effectively creating a multitude of individual lasers off of a single very powerful (5kW) laser. DeMuth and his team demonstrated in 2015 that it would be possible to use this system to weld a large area on the powder bed in an instant. In January 2021, Seurat (which was founded in 2016 and raised 33 million so far in venture capital), demonstrated printing stainless steel with mechanical properties that exceeded industry standards.

The company is now ready to scale and go to market. In fact, Area Printing is all about scalability: scaling volume to meet end-use production requirements, but also scaling size, to print the large parts demanded by industrial applications. Without the spatter and soot typically generated by full-melt metal AM processes, future Area Printing systems are aiming to meet industrial-sized challenges head-on.

The Optically Addressed Light Valve is the key enabling technology that lets Seurat scale AM printing rates without losing resolution.

Key areas of applications for Seurat have been identified as the automotive and consumer products industries. The next generation of automotive manufacturing faces unprecedented challenges to meet a market-moving rapidly toward electrification. Agile yet resilient supply chains will be needed to respond to changing product needs. Area PrintingTM brings all the advantages of AM in a scaleable product that can meet the volume and price demands of the industry while delivering the quality required for end-use automotive components. While high accuracy with high volume are two attributes not normally associated with metal additive manufacturing. These technical barriers have so far limited the uses of metal AM in consumer tech to prototyping and high-end customized solutions. Area Printing’s two million points of laser light offer micron-scale resolution with massive parallel processing – unlocking the capability to print high volume, net-shape parts without tooling. Let it shine.

 

Research 2021
Metal AM Market Opportunities and Trends

This market study from 3dpbm Research provides an in-depth analysis and forecast of the three core segments...

Davide Sher

Since 2002, Davide has built up extensive experience as a technology journalist, market analyst and consultant for the additive manufacturing industry. Born in Milan, Italy, he spent 12 years in the United States, where he completed his studies at SUNY USB. As a journalist covering the tech and videogame industry for over 10 years, he began covering the AM industry in 2013, first as an international journalist and subsequently as a market analyst, focusing on the additive manufacturing industry and relative vertical markets. In 2016 he co-founded London-based 3dpbm. Today the company publishes the leading news and insights websites 3D Printing Media Network and Replicatore, as well as 3D Printing Business Directory, the largest global directory of companies in the additive manufacturing industry.

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