The First Company to Qualify 4140 via Metal
Binder Jetting for the Mass Production of Strong Steel Parts That
Withstand High Impacts, Temperatures and Mechanical
Stresses
Desktop Metal (NYSE: DM), a leader in mass production additive
manufacturing (AM) solutions, today announced it has qualified the
use of 4140 low-alloy steel for the Production SystemTM platform,
which leverages patent pending Single Pass JettingTM (SPJ)
technology designed to achieve the fastest build speeds in the
metal additive manufacturing industry. Desktop Metal is the first
and only company to qualify 4140 low-alloy steel for use with metal
binder jetting systems, enabling its use in mass production end-use
part applications.
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Desktop Metal is the first and only
company to qualify 4140 low-alloy steel for use with metal binder
jetting systems, enabling its use in mass production end-use part
applications. Considered one of the most versatile low-alloy
steels, 4140 is a critical all-purpose and heat-treatable steel
used extensively in a variety of automotive, oil and gas, and
industrial applications, such as gears, downhole tool components,
couplings, spindles, bolts and nuts, and many other mechanical
parts. This linear pneumatic piston is used to convert air pressure
into rotary motion through a rack and pinion with 4140 providing
the toughness and wear resistance required for this application.
The Production System P-50 enables production of up to 690,000
parts per year at a cost as low as $0.28 per cubic centimeter of
sintered 4140 low-alloy steel. (Photo: Business Wire)
Considered one of the most versatile low-alloy steels, 4140 is
characterized by its toughness, high tensile strength, and abrasion
and impact resistance. It is a critical all-purpose and
heat-treatable steel used extensively in a variety of automotive,
oil and gas, and industrial applications, such as gears, downhole
tool components, couplings, spindles, bolts and nuts, and many
other mechanical parts.
“4140 has been a challenging material for metal binder jetting
because of its low alloyed content, tight carbon control
requirements, and low ignition energy, which together require
advanced binder chemistry, as well as extensive printing and
sintering optimization and atmospheric controls for safe
processing,” said Jonah Myerberg, co-founder and CTO of Desktop
Metal. “We are excited to be the first to qualify 4140 for metal
binder jetting to enable this versatile material for the AM
industry. With the speed of the Production System, businesses can
now use binder jetting to print complex 4140 parts at competitive
costs while maintaining the strength and mechanical properties of
traditionally manufactured alternatives. This is a game-changing
solution for manufacturers who have been tied to time-consuming and
expensive machining and conventional tool-based manufacturing
processes.”
4140 Low-Alloy Steel - Key Applications
Desktop Metal’s materials science team has validated that 4140
low-alloy steel printed on Production System technology and
sintered by Desktop Metal meets MPIF 35 standards for structural
powder metallurgy parts set by the Metal Powder Industries
Federation. 4140 parts printed on the Production System platform
not only eliminate the use of tooling and minimize material waste,
but also represent a significant decrease in production time and
part cost compared to conventional manufacturing methods.
- Power Steering Joint This joint is used for power
transfer between an electric power steering motor and the steering
shaft in an automobile. 4140 provides excellent strength and
hardness, which is essential for the spline teeth that connect this
part to the rest of its assembly. While production using a
conventional press and sinter process would require an expensive
mold, the Production System P-50 enables production with no
tooling, reducing lead times and enabling more flexible design for
quantities up to 1.2 million per year at a fully burdened part cost
as low as $2.45.
- Herringbone Gear Herringbone gears, which are found in a
variety of industrial machinery applications, benefit from the
excellent hardness of 4140 low-alloy steel and can be lightweighted
using complex lattice designs made possible by additive
manufacturing, reducing material cost and reducing wear on external
components, such as motors and bearings. This part can be mass
produced on the Production System P-50 in quantities up to 200,000
per year with 120 parts nested in each build.
- Linear Pneumatic Piston Linear pneumatic pistons are
used to convert air pressure into rotary motion through a rack and
pinion with 4140 providing the toughness and wear resistance
required for this application. These parts are traditionally
assembled from multiple components due to the geometry and cost
limitations of conventional manufacturing processes. The Production
System P-50 enables production of up to 690,000 parts per year at a
cost as low as $0.28 per cubic centimeter of sintered 4140
low-alloy steel.
- Lever Drive Lever drives are often used in machine
design to linearly adjust the location of components in a machine.
Binder jetting easily facilitates features such as the precise
grooves critical for locating the correct position of external
components. While producing a mid-volume run of 10,000 parts would
not be cost-effective with conventional manufacturing given the
upfront tooling costs or the labor costs associated with machining,
the Production System P-50 can print the required quantities in a
day with sintered parts ready in less than a week.
The Production System - the World’s Fastest Way to 3D Print
Metal Parts At-Scale
Created by the inventors of binder jetting and single-pass
inkjet technology, the Production System is an industrial
manufacturing platform powered by Desktop Metal’s SPJ technology.
It is designed to achieve speeds up to 100 times those of legacy
powder bed fusion additive manufacturing technologies and enable
production quantities of up to millions of parts per year at costs
competitive with conventional mass production techniques.
The Production System platform consists of two printer models:
the P-1, a solution for process development and serial production
applications, and the P-50, a large form factor mass production
solution for end-use parts, scheduled to begin commercial shipments
in the second half of 2021. The Production System combines Desktop
Metal engineered binders with an open material platform, allowing
customers to produce high-performance parts using the same low-cost
metal powders used in the Metal Injection Molding (MIM) industry.
An inert processing environment enables compatibility with a
variety of materials, including 4140 low-alloy steel as well as
other high-performance alloys and even reactive metals, such as
aluminum and titanium. To learn more about the Production System,
visit: www.desktopmetal.com/products/production.
Today, the Production System platform materials library includes
17-4 PH stainless steel, 316L stainless steel and 4140 low-alloy
steel, each of which have been qualified by Desktop Metal. The
platform also supports several customer-qualified materials,
including silver and gold, and Desktop Metal plans to add
additional metals to its portfolio, including tool steels,
stainless steels, superalloys, copper, and more. To learn more
about 4140 and the Production System materials portfolio, visit:
www.desktopmetal.com/materials.
About Desktop Metal
Desktop Metal, Inc., based in Burlington, Massachusetts, is
accelerating the transformation of manufacturing with an expansive
portfolio of 3D printing solutions, from rapid prototyping to mass
production. Founded in 2015 by leaders in advanced manufacturing,
metallurgy, and robotics, the company is addressing the unmet
challenges of speed, cost, and quality to make additive
manufacturing an essential tool for engineers and manufacturers
around the world. Desktop Metal was selected as one of the world’s
30 most promising Technology Pioneers by the World Economic Forum
and named to MIT Technology Review’s list of 50 Smartest Companies.
For more information, visit www.desktopmetal.com.
Forward Looking Statement
This press release contains certain forward-looking statements
within the meaning of the federal securities laws. Forward-looking
statements generally are identified by the words “believe,”
“project,” “expect,” “anticipate,” “estimate,” “intend,”
“strategy,” “future,” “opportunity,” “plan,” “may,” “should,”
“will,” “would,” “will be,” “will continue,” “will likely result,”
and similar expressions. Forward-looking statements are
predictions, projections and other statements about future events
that are based on current expectations and assumptions and, as a
result, are subject to risks, uncertainties. Many factors could
cause actual future events to differ materially from the
forward-looking statements in this document, including but not
limited to the risks and uncertainties set forth in Desktop Metal,
Inc.'s filings with the U.S. Securities and Exchange Commission.
These filings identify and address other important risks and
uncertainties that could cause actual events and results to differ
materially from those contained in the forward-looking statements.
Forward-looking statements speak only as of the date they are made.
Readers are cautioned not to put undue reliance on forward-looking
statements, and Desktop Metal, Inc. assumes no obligation and does
not intend to update or revise these forward-looking statements,
whether as a result of new information, future events, or
otherwise.
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version on businesswire.com: https://www.businesswire.com/news/home/20210603005532/en/
Press Lynda McKinney lyndamckinney@desktopmetal.com
978-224-1282
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