InnoZone: ADDiTEC Presents Multi-Metal 3D Printing Process

Additive Technologies (AddiTec) developed an innovative solution to manufacture gear components for Amorphology Inc. using Meltio’s laser metal deposition (LMD) process. The prototype gear component was manufactured using two different steels printed together within the same component. The three-inch diameter Flexspline demonstrator is a part of zero backlash strain wave gearbox used in robotic arms and precision motion mechanisms. The thin-walled Flexspline has competing requirements of wear resistance in the teeth and a fatigue-resistant body that motivates the use of two different materials during the fabrication. The steel in the toothed region is a precipitation hardening martensitic stainless steel typically used in high-strength applications with an average hardness of 35 Rc. In contrast, the steel below the toothed region is known for high toughness with a lower average hardness. By combining the two steels strategically in a gear, it becomes possible to tailor the mechanical properties to take advantage of the benefits of each alloy. This case-study will talk about the novel multi-metal LMD process, explain the methodology developed for building this demonstrator, and compare the manufacturing costs and times with the traditional approach.