Advanced Process Control for Support Reduction
The new EOS process control solution includes first-of-its-kind, real-time intelligent heat management; reducing or eliminating support structures and performing 2x-5x faster than other technologies. Smart Fusion is the latest EOS advance in metal additive manufacturing (AM) through innovative solutions that simplify the process, save costs and increase productivity
How does EOS’s Smart Fusion affect manufacturing processes?
Smart Fusion intuitively detects potential build problems, auto-adjusts the laser power, and eliminates wasted time and resources typically associated with “trial and error” additive manufacturing. Unlike current technologies, Smart Fusion’s real-time capabilities are achieved without adding significant build-time.
Smart Fusion solution has consistently resulted in performance that is two to five times (2x-5x) faster than the leading competitors in the metal AM market. Lower CPP is a primary business driver for the adoption of Smart Fusion. Removing the need for support structures in metal AM makes for a more attractive business case. EOS partnered with several organizations during Smart Fusion’s testing phase where its speed and performance were validated.
This novel software approach provides a solid business case for additional AM metal applications, particularly in highly technical industries such as energy, space technology, transportation, and aerospace.
Smart Fusion is another important breakthrough for metal AM, especially for those organizations with highly engineered applications, such as energy, space tech, mobility, and aerospace. Other solutions in the market have significant drawbacks such as slower build times, and a need for an expert to make sure it works. Smart Fusion offers an industrialized solution that is faster, flexible, and more accessible.
Mirco Schöpf, EOS product line manager, software
How does Smart Fusion work?
Smart Fusion measures the amount of laser power (energy) which is absorbed by the powder bed using complex algorithms. A special high-resolution camera overlooking the build chamber monitors each layer’s meltpool emissions via proprietary technology and data is fed back to the laser where it is adjusted. This results in homogeneous energy distribution across the whole build platform thereby reducing stress in the parts and avoiding metal overheating and movement in undesired directions.
Using this technology, support structures can be avoided or even eliminated. This not only saves time, but it also reduces your cost per part (CPP) by reducing post-processing and material utilisation.
At its core, Smart Fusion pairs with EOS’ existing monitoring solutions and employs advanced algorithms to monitor the build layer-by-layer providing for more homogeneous, consistent parts. From a dataflow perspective, EOSPRINT prepares the data which is sent to the 3D printer, Smart Fusion then works with EOSTATE and its Optical Tomography (OT) camera to monitor, measure, and adjust the lasers via EOSYSTEM.
The EOS Smart Monitoring System package, and is available now for on the following EOS system and materials:
| EOS M 290 | EOS M 300-4 | EOS M 400-4 | |
|---|---|---|---|
| Material | Inconel IN718 HiPro 40/80μm | Inconel IN718 HiPro 80μm | Inconel IN718 HiPro 40/80μm |
| Material | Titanium Ti64 60μm | Ti64 60μm (late 2023) | Titanium Ti64 60μm |
| Material | Aluminum AlSi10Mg 60μm (late 2023) | Aluminum AlSi10Mg 60μm (late 2023) | Aluminum AlSi10Mg 40/80μm |