With the objective of saving manufacturers time and money on the production of large, high-value metal parts and prototypes, Sciaky Inc., a subsidiary of Phillips Service Industries (PSI), launched its Direct Manufacturing (DM) technology, which is based on additive manufacturing principles, in 2009. DM is a large-scale, fully programmable means of achieving near-net shape parts made of titanium, tantalum, inconel and other high-value metals, ranging up to 19 ft in length, 4 ft in width and 4 ft high. The technology combines computer-aided design (CAD), state-of-the art electron beam welding technology, and layer-additive processing. Starting with a 3D model from a CAD program, the fully articulated, moving electron beam welding gun deposits metal, layer by layer, until the part is complete and ready for finish machining. Deposition rates typically range from 7 to 20 lb per hour, depending upon part geometry and the material selected.

Over the past two years, this technology has been at the heart of several key advanced research and development programs with the Department of Defense (DoD), U.S. Air Force, Lockheed Martin, Boeing, DARPA and Penn State University’s Applied Research Laboratory.

Sciaky Inc.
www.sciaky.com

Phillips Service Industries, Inc.
www.psi-online.com