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You are here: Home / EOS Smart Fusion

EOS Smart Fusion

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

OT exposure image versus Laser correction factor (LCF) image. • LCF is used to adjust the laser power and correct areas of the part that are overheating • Correction factors are calculated based on the OT images and the controller settings within Smart Fusion software.Smart Fusion Laser correction factor example | © EOS GmbH

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.

3D printed part leveraging EOS Smart Fusion software, supports greatly reduced.
• Optical Tomography software using internal camera to record long-term exposure of each layer and correct
• feedback loop managing heat distribution
• creating homogeneous part temperature distributionPart with Smart Fusion vs. without example | © EOS GmbH

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 290EOS M 300-4EOS M 400-4
MaterialInconel IN718 HiPro 40/80μmInconel IN718
HiPro 80μm
Inconel IN718
HiPro 40/80μm
MaterialTitanium Ti64 60μmTi64 60μm (late 2023)Titanium Ti64 60μm
MaterialAluminum AlSi10Mg 60μm (late 2023)Aluminum AlSi10Mg 60μm (late 2023)Aluminum AlSi10Mg 40/80μm
EOS intends to soon expand Smart Fusion availability, including AMCM systems.

Want to learn more about the new “Smart Fusion” technology? 

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