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SLM Solutions 280 Additive Manufacturing Machine
SLM Solutions

SLM Solutions, Burgmaier strengthen partnership in tooling, hybrid manufacturing

Burgmaier introduced case-hardening steel 16MnCr5 to AM, and developed a hybrid-AM process using the SLM 280.

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Additive Manufacturing pioneer SLM Solutions and high precision metal parts processor, Burgmaier have been working together for more than three years to redefine what is possible in part processing. The partnership is founded on the technical excellence of both sides coming together to open new possibilities in the tooling industry and hybrid manufacturing.

As the technology leader in metal part processing, Burgmaier actively seeks out innovations to push the industry forward and to create products of the absolute highest quality. With the help of SLM additive manufacturing technology, they have already improved the efficiency, design, and manufacturing cost of various components, including AM-cutting-tools, manufacturing equipment such as nozzles or claws, and casting molds, all to great success.

Burgmaier pushes the limits for innovative tooling. 16MnCr5 – a favorite material for the tooling industry – combines a very hard surface with a ductile core, and various heat treatments can flexibly adjust its characteristics to the customer’s needs. Today, Burgmaier has established a technique of hybrid manufacturing using various steels such as 1.2709 or 16MnCr5: an innovation that allows them to manufacture with the highest precision.

The introduction of case-hardening-steels to AM is a game changer: a new world of hard-wearing designs is now possible – from lightweight tools with flexible cooling channels to resistant and cost-efficient molds. The hybrid-manufacturing process includes an innovative, self-developed system to clamp various base bodies and a standardized approach to manufacture the parts additively in a SLM 280, enabling single-use and series production with the highest accuracy. Burgmaier achieves a positioning and repeating accuracy of fewer than 0.05mm and a high-quality joint of the base body and the AM part. Despite the challenges of the Covid crisis in 2020, Burgmaier decided to invest in developing both innovations (16MnCr5 and hybrid-AM-process). This kept Burgmaier at the forefront of innovation and gave them a competitive edge on an already leading market position.

“We are a partner-like solution provider for complex challenges with a high-quality standard. Curiosity and precision drive us to develop the right solution with and for our customers. We provide the advantages of additive, subtractive and hybrid manufacturing from a single source,” says Ken Krauss, director additive manufacturing Burgmaier.

At the heart of the partnership stands the revolutionary SLM 280. Its legendary multi-laser, closed-loop powder handling has earned it the informal title of The Dual-laser Trailblazer, a system ideal for medium to high volume metal part production and prototyping. The multi-laser systems can build at an astounding 80% faster rate than a single laser, and the patented bi-directional powder recoating boosts productivity by reducing overall manufacturing time. Material flexibility makes it’s the perfect build companion for several industries, from aviation and aerospace to automotive and energy.

SLM Solutions CEO Sam O’Leary points to Burgmaier’s experience and innovative thinking as a key factor in the success of the partnership, saying “It’s a partner like that of Burgmaier that is a testament to the deep collaboration necessary to achieve extraordinary new heights of technological advancement. This is not a one-and-done story, but a series of success that we will continue to build upon, together.”

A major business case will be presented at the SLM booth at EMO Milano 2021, the world leading trade fair for metalworking: An AM-cutting-tool, all additive and hybrid, lightweight design, and innovative cooling channels, ramping up to high series on SLM 280 in the upcoming months.