Photon Forge Additive Manufacturing Facility

The Photon Forge Additive Manufacturing (PFAM) facility is a centralised hub for metal additive manufacturing at Curtin University under the direction of the John de Laeter Centre (JdLC). The PFAM facility is equipped with deposition based additive equipment for both small- and large-scale manufacturing, with the availability to process a range of alloy systems. The PFAM facility assists research, development, and training activities in additive manufacturing (AM) by leveraging existing material characterisation and analysis facilities, along with industrial collaborations. Cutting edge characterisation equipment at the JdLC complements the additive manufacturing process, enabling part quantification and characterisation.

The PFAM team conducts high quality research and engages with partners, both nationally and internationally, in government and industry to deliver targeted solutions to real world problems in the defence, mining, drilling, oil & gas, critical minerals, and energy sectors. With expertise in the following areas; design for AM, materials characterisation, qualification and certification of engineering materials and alloy development for AM.

Equipment

AML3D ARCEMY – Wire Arc Additive Manufacturing (WAAM) system

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Fast manufacturing of parts at a range of length scales through the 8-axis robotic arm deposition of a wide range of welding suitable alloy wire systems.

Production versatility: Part repair, surface coating (wear + corrosion), hybrid manufacturing, combined manufacturing with final coating by LaserBond DED

Alloys: Stainless Steels (316L, 420, duplex), steels, Aluminium alloys (2xxx, 4xxx, 5xxx), Copper alloys, Nickel alloys (Invar, Inconel), Titanium alloys (Pure Ti and Ti6Al4V)

Max Part size – ~1.5×1.5×1.2m

Minimum Resolution: 5x4mm (hxw)

 

LaserBond – Directed Energy Deposition (DED) system

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Adaptable manufacturing, repair or coating of components at a range of length scales from low volumes (<10kg) of pre- or in-situ alloyed powders, with a high level of process tuneability in the manufacture of functional alloy gradients or multi-material structures.

Production versatility: Part repair, surface coating (wear & corrosion), hybrid manufacturing, combined manufacturing with structure manufactured by ARCEMY WAAM

Alloys: Stainless Steels, Steels, Aluminium alloys, Nickel superalloys e.g. Inconel, High Entropy alloys, Titanium alloys, pure metals, refractory alloys e.g. Tungsten, Molybdenum, metal matrix composites, Exotic alloy development

Max Part size: ~1x1x1.2m

Minimum Resolution: 1x1mm (hxw)

 

Desktop Metal Studio – Bound metal deposition (BMD) system

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Small scale office based production system printing parts from bound metal rods containing a metal powder + binder (green part), followed by chemical removal of the binder (brown part) and sintering of a dense metal component.

Production readiness: High resolution parts (>0.4mm) with structures comparable to conventional powder sintering processes (metal injection moulding)

Alloys: Stainless Steel (316L, 17-4PH), Copper, Tool Steel (D2, H13, A2), steel 4140, Inconel 625, titanium Ti6Al4V

Max Part size: ~100x100x100mm

Minimum Print Resolution: 0.8×0.8mm (hxw)

 

Capabilities

The following is a list of capabilities for the AM systems at the PFAM facility.

AML3D ARCEMY – Wire Arc Additive Manufacturing (WAAM) system

  • Large scale component production
  • Tooling production
  • Part repair
  • Surface coating
  • Hybrid manufacturing
  • Rapid part production

LaserBond – Directed Energy Deposition (DED) system

  • Large scale component production
  • Tooling production
  • Part repair
  • Surface coating
  • Hybrid manufacturing
  • Exotic Alloy development
  • Functionally graded alloys
  • Multi material production

Desktop Metal Studio – Bound metal deposition (BMD) system

  • Direct to print production
  • Small scale production
  • Legacy part manufacture
  • Prototyping & Small tooling
  • Electrically conductive part production
  • Fine detail manufacturing

 

Applications & Industries

Some of the many applications and industries the equipment at PFAM can cater to:

Applications:

  • Ship building
  • Mining- hard faced tooling
  • Oil & Gas- corrosion resistant components
  • Automotive & Motorsport- Suspension & engine components
  • Defence – rapid & custom production
  • Electromagnetic Shielding
  • Satellite components
  • Space launch vehicles
  • Tooling- Composites & polymers
  • Legacy part manufacture
  • Filtration
  • Medical devices & implants
  • Jewellery + Watches
  • Art installations
  • Heat exchangers
  • Jet turbines
  • Catalysis

Industries:

  • Maritime
  • Defence
  • Mining
  • Energy + Oil & Gas
  • Automotive & Motorsport
  • Agriculture
  • Space
  • Medical & Dental
  • Art & Design
  • Construction
  • Pharmaceutical
  • Food & Beverage
  • Chemical processing