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Breakthrough in C103 Powder Recycling for Aerospace Material…

InssTek's advanced material research tool, the MX-Lab system, has successfully demonstrated C103 niobium alloy powder recycling for Laser Powder Directed Energy Deposition (LP-DED) processes. The development of recycling in powder analysis and materials testing technology resolves the increased cost of C103, which has constrained its use cases despite its outstanding performance attributes. Advanced Materials Testing Capabilities MX-Lab material research tools represent a key development in powder characterization technology, merging extensive analysis abilities with advanced testing methods. Integrating material testing systems supplies researchers and engineers with the appropriate instruments for comprehensive powder analysis and quality validation, which are key for developing aerospace materials. Research Significance and Material Analysis The importance of this material research extends beyond historical powder testing systems. C103, a niobium-based alloy known for its higher performance in extreme settings, has seen limited uptake owing to financial constraints. Using sophisticated powder analysis methods undertaken in the MX-Lab system, scientists have shown that recycled C103 powder preserves its important characteristics when processed in controlled settings. Comprehensive Testing Methodology The research used advanced material testing tools to validate the recycled powder's performance. Scanning electron microscopy (SEM) analysis, an essential part of the powder characterization process, showed consistent particle size distribution between virgin powder (101.77 μm) and argon-recycled powder (100.81 μm). This exact powder analysis ability proves critical for aerospace materials testing and quality assurance. The material research equipment's sophisticated testing abilities made detailed chemical composition analysis possible, which is especially important for developing aerospace materials. Testing carried out in controlled settings showed minimal oxidation levels and maintained particle morphology. The system's integrated flowability testing, in accordance with ASTM B213/B212 standards, verified the recycled powder's suitability for sophisticated manufacturing processes. Performance Validation Through Materials Testing MX-Lab's material testing equipment produced especially significant results in validating mechanical performance. Tensile testing carried out as per ASTM E8 criteria showed that parts manufactured from recycled powder achieved significant tensile strength values of around 500 MPa, matching virgin material performance. The advanced powder testing system maintained a consistent yield strength of approximately 300 MPa, meeting stringent aerospace industry standards. InssTek underlies the significance of sophisticated materials testing: "The MX-Lab's comprehensive powder analysis capabilities have proven essential in validating the recycling process. This material research equipment allows us to maintain precise control over every aspect of powder characterization and testing." Industrial Applications for Advanced Material Research The validated powder recycling technology facilitates wider use of C103 in important aerospace parts. The sophisticated manufacturing system has proven especially valuable in fabricating parts for rocket nozzles, where material performance is crucial. Similar use cases also apply to supersonic engine components and nuclear fusion reactor parts, where the material research tools’ precision and reliability guarantee consistent quality in recycled powder use cases. Future Prospects in Materials Development The ability to recycle C103 niobium alloy powder is a key development in powder analysis and materials testing technology, which enables new possibilities in developing aerospace materials. MX-Lab's sophisticated material research abilities resolve cost issues and establish novel standards in powder recycling technology and materials testing methodology. InssTek continues to increase the capabilities behind its material research tools, exploring applications beyond C103 to other crucial aerospace materials. Such progression of powder testing systems and material analysis technology entails broader potential for the future of advanced manufacturing and materials research.

Game-Changing Advances in Metal 3D Printing for Aerospace Sy…

A key metal additive manufacturing technology development has transformed the aerospace manufacturing landscape. Collaborating scientists from InssTek and the Korea Aerospace Research Institute (KARI) have built a 3-ton rocket nozzle system that utilizes Directed Energy Deposition (DED) technology. The system shows unparalleled multi-material metal 3D printing abilities for crucial aerospace use cases. Advancing Metal Additive Manufacturing Implementing DED represents a key development in metal 3D printing abilities. Unlike historical manufacturing techniques or commonplace powder bed fusion processes, DED technology enables the processing of multiple materials simultaneously, providing frictionless transitions between different metals within a single component. The ability to process multiple materials has proven especially valuable in aerospace use cases, where diverse material characteristics are needed within a single component. Innovation in Material Integration The development of the rocket nozzle system demonstrates the advanced material integration abilities of contemporary metal additive manufacturing. This innovation's core is a sophisticated bi-metallic structure that merges different materials to reach outstanding performance properties. The nozzle's central body has an intricate design, with an interior structure made of Al-Bronze, a copper alloy chosen for its superior thermal characteristics. This interior construction merges cooling channels spaced at exact 1 mm intervals, a feat enabled by the precise control enabled by DED technology. The nozzle’s exterior uses Inconel 625, a nickel alloy known for its structural strength and temperature resistance. This combination of materials represents the benefits of multi-material additive manufacturing, where every material has a certain functional purpose within the part. The nozzle extension further demonstrates material optimization by incorporating C-103, a specialized niobium alloy selected for its outstanding performance in extreme thermal settings. Manufacturing Process Validation Stringent testing and validation processes have marked the advanced manufacturing process’s development journey. The manufacturing team performed detailed tests to check the parts’ material integration and functional performance. Hot-fire testing of the complete nozzle assembly has shown the cooling channel design’s effectiveness, while comprehensive analysis has verified the material interfaces’ structural integrity. InssTek highlights the importance of this accomplishment in manufacturing: "The successful integration of multiple materials in a single component represents a fundamental advancement in metal additive manufacturing. Our DED technology enables us to precisely control material placement and properties, opening new possibilities in aerospace component design and manufacturing." Industrial Applications and Future Implications The development of DED technology represents a manufacturing breakthrough that surpasses producing rocket nozzles. With proven success in building complex, multi-material parts also has important implications for multiple aerospace and industrial use cases. DED technology is particularly promising for the manufacturing of heat exchangers, where combining materials with a range of thermal applications could transform design techniques. Improved metal 3D printing technology will greatly benefit the aerospace industry. Manufacturing parts with optimized material characteristics using DED will support novel methods in thermal management and structural design. This ability could lead to more efficient and reliable aerospace parts, ranging from propulsion systems to structural components. Industrial manufacturing may also find valuable use cases for this technology. The ability to generate bimetallic structures with precise material transitions opens up new possibilities for equipment built to withstand extreme conditions. Moreover, the technology's ability to integrate cooling channels in the manufacturing process could increase the efficiency of multiple industrial systems.

KARI develops radiative cooling nozzle to reduce rocket laun…

KARI pioneers innovative cooling technology to enhance rocket engine efficiency and affordability Domestic researchers successfully conducted performance tests on the 'Radiative Cooling Nozzle' that cools rocket engines. The radiative cooling nozzle helps the engine withstand internal heat through a radiation method that naturally dissipates heat, which can reduce launch expenses. If successful, it is expected to contribute to domestic rockets. According to the Korea Aerospace Research Institute (KARI) on the 24th, researchers from the small launch vehicle research division recently applied the radiative cooling nozzle to a methane-oxygen combustor and successfully verified the technology to effectively dissipate the engine's heat during a maximum combustion time of 60 seconds. The rocket engine burns fuel inside the combustion chamber. The high-temperature and high-pressure combustion gases are expelled through a conical nozzle to gain propulsion. The temperature of the combustion gases can exceed 3,500 degrees Celsius. If the heat from the combustion gases is not dissipated in time, it can lead to fires or cause parts to melt and fail. Thus, technology managing the engine's heat is a critical factor that determines launch success. The KARI researchers created the nozzle using high-temperature resistant materials, allowing the engine to naturally dissipate heat without additional cooling. This method, known as the radiative cooling nozzle, has the advantage of a simpler structure compared to existing cooling methods, thereby reducing engine manufacturing and maintenance expenses and lightening weight. The researchers used a 3D (three-dimensional) printer to make the nozzle with niobium (Nb) alloy powder as ink. The nozzle surface was coated with an oxidation-resistant layer. Recent verification experiments confirmed that the radiative cooling nozzle effectively dissipated internal heat while maintaining engine performance. The engine operated for 60 seconds and produced high-temperature combustion gases; however, no damage occurred to other components due to the use of the radiative cooling nozzle. Kim Hyun-jun, the lead researcher who developed the radiative cooling nozzle, noted, "Due to the characteristics of metal materials, the nozzle expansion section oxidizes at high temperatures, making coating technology important," and added, "This technology is classified as a strategic technology, making it challenging to apply foreign technology domestically. The fact that we developed the technology in collaboration with domestic companies InssTek and Bedell Surface Treatment Research Center is significant." The ultimate research goal is to secure radiative cooling nozzle technology that continues throughout the nozzle expansion section where combustion gases are expelled. The researchers stated that applying the radiative cooling method to the nozzle expansion section could reduce the engine's weight and manufacturing expenses without compromising rocket performance. Previously, the regenerative cooling method used in the Naro and Nuri rockets has the disadvantage of increasing thickness within the engine, which simultaneously increases the overall weight. Applying radiative cooling technology allows cooling of the engine without additional structures, significantly reducing engine weight. This is effective in reducing launch expenses. It is already utilized in the upper engine of SpaceX's Falcon 9. Kim Hyun-jun, the lead researcher, remarked, "It's more significant that we confirmed the potential for the successful development of radiative cooling nozzle manufacturing technology rather than saying we've fully developed it in Korea," adding, "Once complete, we will continue research to secure the essential technology needed for the advancement of rocket engine technology."

The Coolest Metal Applications at Formnext 2024

It goes without saying that at Formnext attendees will see incredible solutions, whether for 3D printing, software or materials. But what should also not be ignored are the amazing applications that different companies are bringing to their booths. At Formnext 2024 especially there have been some incredible metal applications that we have seen around the show in different sectors including aerospace, automotive, dentistry and many more. That’s why we decided to take a look at some of the coolest examples that we saw this year, put below in no particular order. InssTek’s Multi-Material Nozzle The first application that has blown us away at Formnext is undoubtedly the multi-material rocket nozzle present at InssTek’s booth. The 3-ton rocket nozzle (measuring 301 x 201 x 567 mm and made in 600 hours) and extension (432x 270 x 169mm and made in 64 hours) were created using Directed Energy Deposition 3D printing in partnership with the Korea Aerospace Research Institute (KARI). The multi-material factor comes from the fact that each part was manufactured using the optimal material, a unique feature possible with InssTek’s DMT technology. For example, in the nozzle itself, the inner part is made of Al-Bronze with a cooling channel at 1mm intervals while the outer part is made of Inconel 625. Meanwhile, the extension was made using C-103, one of the most exciting materials currently being used in the space industry. The resulting unified, high-performance unit is remarkable because combining these different metals enables the use of the strength of each one, allowing for the creation of intricate structures and functionalities that can enhance the efficiency and reliability of rocket engine components. According to InssTek, this breakthrough is the result of rigorous testing, including successful combustion trials. For example, to ensure the reliability of the multi-materials, each part was produced after verification through material research using the MX-Lab, including tests on tensile strength and thermal conductivity. The hope is that the success of these parts will help open the way for tailored solutions that meet the complex demands of modern aerospace. An incredible feat from the Korean space sector that hopefully will pave the way for even more breakthroughs in the use of additive manufacturing for rocket propulsion. You can learn more about InssTek’s solutions HERE or find out more about the application at InssTek’s booth D98 in hall 12.0 at Formnext.

InssTek Is Revolutionizing Alloy Research Globally With the …

Directed energy deposition (DED) is one of the more versatile metal additive manufacturing technologies. Used for everything from large metal parts to repairs, the process is gaining popularity in different sectors. One area where we are particularly seeing a growing interest in DED printing is in material research. This can be seen with the MX-Lab 3D printer which has been designed for this very purpose. The South Korean industrial 3D printing solution provider, InssTek, has seen significant global success with its metal 3D printing machine, MX-Lab, attracting top universities and research institutions worldwide. The recent sales to the Institut Jean Lamour (IJL) the University of Lorraine have further accelerated MX-Lab’s successful global expansion. Additionally, installations are currently underway at other universities and research institutions especially for those working in metallurgy and alloying, or the mixing of metals to make alloys. But how exactly can DED be used in this for material research? How can you adopt the technology if you have little experience with metal AM? Why would you choose this 3D printer? We took a closer look at the MX-Lab 3D printer to better answer these questions. Not to mention, attendees at Formnext 2024 can also see the machine at InssTek’s Booth, D98, in Hall 12.0. A Closer Look at the MX-Lab 3D Printer Before we can look at the applications, it is necessary to understand the MX-Lab 3D printer itself. As mentioned, this 3D printer uses DED 3D printing with InssTek’s very own Direct Metal Tooling (DMT®) technology. This process from the Korean manufacturer is notable for being one of the most precise forms of DED technology with powder being melted directly by a laser and with two vision cameras that can analyze and control the height of the melt pool in real-time. The MX-Lab has been designed as an entry-level solution for the DED process, making it even more accessible to research applications. The build volume of the MX-Lab measures 150 x 150 x 150 mm and it uses a Ytterbium Fiber Laser. The compact size allows researchers to design and conduct experiments with flexibility and ease. The max power of the laser is 500 watts, with an average wattage of about 300. Furthermore, the solution has been designed for easy installation and has been specially optimized for material research. Its user-friendly interface and advanced capabilities enable scientists and engineers to explore a wide range of material compositions and properties efficiently. Due to this, the printer boasts a number of interesting features for researchers. The most notable feature of this printer is its “Hexa Powder Feeder” system, which allows for the precise control of up to six different material ratios during experiments. This system ensures accurate powder feeding, even in micro-amounts, making it ideal for detailed and precise research applications. For example, it is optimized for High Entropy Alloy (HEA) research. The feeder is able to speed-scan alloys of various compositions during 3D printing, enabling material research to be carried out quickly. Other features include auto powder calibration, an automatic adjusting of the z-layer, the ability to set the appropriate laser powder for the material at the desired location for multi-material samples and a monitoring system. The latter monitors parameters like laser power, melt pool image, coordinate system and powder feeding system, providing data extraction capabilities for the user. A huge boon when it comes to research. Using DED 3D Printing for Material Research Looking at its features, it is understandable why MX-Lab 3D printer has been making some waves in the material research sector. Indeed, already 40 units have been sold in 15 countries worldwide including the USA, Europe and of course Asia. And the use cases show that it is very well-suited to material research in particular. Take the example of HEA research, alloys that are formed by mixing equal or relatively large proportion of five or more elements. These alloys tend to have higher strength, higher hardness and a high corrosion resistance compared to standard alloys and metals.  This makes them particularly attractive in fields like mold manufacturing, aerospace, anti-radiation and more. And it is one of the more popular ways that researchers are using the MX-Lab 3D printer, for example at KAIST in South Korea. Further applications can be seen over a number of prestigious research institutions. For example, in the USA, Brown University is using the MX-Lab 3D printing for innovative research in materials science and engineering. At the University of Michigan meanwhile, researchers have been conducting studies on high-performance alloys and 3D printing process optimization. Then at the University of North Dakota, the MX-Lab is being used to develop multi-material structures and machine learning applications in 3D printing. Applications in other countries, including at the VTT in Finland where they are working on finding an improved alloy by changing the composition of an existing alloy. Finally, COMTES FHT a.s. in the Czech Republic is using the 3D printer to make FGM samples. Standing for Functionally Gradient Materials, these are remarkable for their ability to include variation in composition or microstructures over volume, thus allowing for changes in the properties of the material and allowing them to be designed for specific function and applications. Only 3D printers like the MX-Lab would be able to create them. Numerous publications in esteemed journals have also showcased the versatility and high performance of the MX-Lab in various research domains. An InssTek spokesperson concludes, “The high interest and trust in MX-Lab’s performance and potential from research institutions are driving our success in the global market. We aim to continue partnering with more institutions to contribute to innovative technology development.” You can learn more about the MX-Lab 3D printer HERE. And be sure to check it out at Formnext at Booth D98, in Hall 12.0 if you are interested in seeing directly how it can be used for material research. What do you think of the MX-Lab 3D printer and its applications in material research? Let us know in a comment below or on our Facebook and Twitter pages! Don’t forget to sign up for our free weekly Newsletter, with all the latest news in 3D printing delivered straight to your inbox!

InssTek to unveil its innovative AM developments at Formnext…

South Korean industrial 3D printing solutions provider InssTek will showcase its material research and aerospace manufacturing solutions range at Formnext 2024 in Hall 12.0, Booth D98. Featured technologies include the MX-Lab 3D printer, designed for precise alloy research, and multi-material aerospace components, such as a rocket nozzle and nozzle extension that have undergone rigorous testing. Attendees at the tradeshow will have a chance to explore these technologies and gain insight into InssTek’s work in additive manufacturing and metal 3D printing. MX-Lab 3D printer for material research One of the highlights of InssTek’s display is the MX-Lab, a metal 3D printer tailored for material research with precise In-Situ Alloying capabilities using six independently controlled powder feeders. Operating with a Ytterbium Fiber Laser at 300 W, adjustable to 500 W, the printer is equipped with DMT Closed-Loop Control to maintain consistency in deposition. InssTek’s MX-Lab OS supports compatibility and fine-tuned control over a wide range of material compositions. MX-Lab’s build volume measures 150 x 150 x 150 mm with a fixed beam diameter. Designed to meet the demands of research settings, the compact system includes six powder feeders with a feed rate of up to 0.03 – 2 g/min, based on Ti-6Al-4V material. The printer’s size, at 680 x 684 x 835 mm and approximately 220 kg, makes it a practical addition to laboratories. Through its Clogged Vibration Method (CVM) system, the MX-Lab achieves a stable powder feed rate, broadening the feeding rate range and enhancing the system’s durability. This technology is compatible with both gravity powder and gas-assisted direct powder supply, making it suitable for various DED applications. CVM technology is also available in standalone powder feeding models, such as PCM Multi/Single units, with a feed rate of up to 15–20 g/min for materials like Ti-6Al-4V. With around 40 units in operation across more than 15 countries, MX-Lab is widely implemented in academic and research institutions, contributing to a growing number of publications on material research. Formnext attendees can explore case studies and watch live demonstrations at InssTek’s booth. Multi-material aerospace components on display In addition to its 3D printer, InssTek will also showcase components developed for the aerospace sector, including a Multi-Material Rocket Nozzle and Nozzle Extension. Tested successfully, this Rocket Nozzle and Nozzle Extension completed 20-second and 60-second firing tests, respectively, with a combined 60-second firing test planned for next year. Built with a cooling channel of aluminum bronze (Cu alloy) with 1mm internal spacing and an outer wall of Inconel 625 (Ni alloy), the Rocket Nozzle demonstrates the versatility of multi-material design. The accompanying Nozzle Extension, constructed from C-103 (Nb alloy), showcases additional high-performance applications. This will be the first time both components are presented together at Formnext 2024, with video demonstrations of their testing available for viewing. DED Technology Zone: in-house innovations InssTek will also introduce visitors to its DED Technology Zone, where the company’s proprietary innovations are highlighted. Key technologies on display include the 5Axis-AM-CAM and LFM2 (Zoom Optics Module). The 5Axis-AM-CAM is a comprehensive 5-axis tool path generator that enables simultaneous 5-axis machining, addressing limitations in existing DED technology. Integrated within the 5Axis-AM-CAM, the MiXO Pro software supports precise tool path generation and simulation, essential for complex geometries and multi-material applications. Additionally, the LFM2 Automatic Zoom Optics allows for real-time adjustments to beam size ranging from 800 µm to 2400 µm, supporting various applications by offering flexibility between rough and smooth structures. Tests have shown that adjusting the beam size from spot diameter measurement (SDM) 800 µm to 1600 µm reduces deposition time by approximately 30%, making the LFM2 ideal for efficient builds, such as cooling channels and layered parts.

Revolutionizing Alloy Research: InssTek’s MX-Lab Gains Globa…

South Korea's industrial 3D printing solution provider, InssTek, has seen significant global success with its metal 3D printing machine, MX-Lab, which continues to attract top universities and research institutions worldwide. The recent sale to the Institut Jean Lamour (IJL)[Joint unit of University De Lorraine & CNRS] further accelerates MX-Lab's successful global expansion. Additionally, installations are currently underway at other universities and research institutions. The MX-Lab, independently developed by InssTek, is a dedicated 3D printer for material research using Directed Energy Deposition (DED) technology. The most notable feature of this printer is its "Hexa Powder Feeder" system, which allows for the precise control of up to six different material ratios during experiments. This system ensures accurate powder feeding, even in micro-amounts, making it ideal for detailed and precise research applications. The MX-Lab is designed specifically for research purposes, offering a compact size that allows researchers to design and conduct experiments with high flexibility and ease. Its user-friendly interface and advanced capabilities enable scientists and engineers to explore a wide range of material compositions and properties efficiently. A testament to MX-Lab's impact on academic research is the steadily increasing number of publications featuring research conducted with this advanced 3D printer. The graph illustrates the surge in research publications featuring InssTek technology since MX-Lab's launch in 2020. This trend reflects the growing recognition of MX-Lab's capabilities in high-quality materials research. Key Customers and Research Achievements The MX-Lab, with its advanced capabilities, has been adopted by several prestigious universities and research institutions across 15 countries, leveraging its technology for groundbreaking research and development. Key customers include: - Brown University (USA) : Focusing on innovative research in materials science and engineering using MX-Lab. - University of Michigan (USA) : Conducting studies on high-performance alloys and 3D printing process optimization with MX-Lab. - University of North Dakota: (USA) : Utilizing MX-Lab for the development of multi-material structures and machine learning applications in 3D printing. - VTT (FINLAND) : To finding an improved alloy by changing the composition of the existing alloy using MX-Lab. - COMTES FHT a.s. (CZECH) : To make a FGM(Functionally Gradient Materials) samples by using MX-Lab - KAIST (SOUTH KOREA) : To find a new composition of HEA(High Entropy Alloy) using MX-Lab. These institutions have published numerous papers in esteemed journals, showcasing the versatility and high performance of the MX-Lab in various research domains.​​​​​​​ Growth in the Global Market InssTek’s MX-Lab has been sold across various regions, including the USA, Europe, and Asia, where it continues to see strong demand due to its reliability and research success. An InssTek spokesperson stated, "The high interest and trust in MX-Lab's performance and potential from research institutions are driving our success in the global market. We aim to continue partnering with more institutions to contribute to innovative technology development."​​​​​​​ The recent sale to Lorraine University once again demonstrates the global recognition of InssTek's innovative solutions. InssTek plans to strengthen its position as a leader in the 3D printing industry through ongoing research, development, and global expansion.

InssTek reports on alloy development success with its MX-Lab…

InssTek, headquartered in Daejeon, South Korea, has reportedly seen significant global success with its metal Additive Manufacturing machine, MX-Lab, which continues to attract leading universities and research institutions worldwide. A recent sale to the Institut Jean Lamour (IJL), Université de Lorraine, Nancy, France, further accelerates MX-Lab’s successful global expansion. Additionally, installations are currently underway at other universities and research institutions. The MX-Lab, independently developed by InssTek, is a dedicated Additive Manufacturing machine for material research using Directed Energy Deposition (DED) technology. The most notable feature of this AM machine is its ‘Hexa Powder Feeder’ system, which allows for the precise control of up to six different material ratios during experiments. This system ensures accurate powder feeding, even in micro-amounts, making it ideal for detailed and precise research applications. The MX-Lab is designed specifically for research purposes, offering a compact size that allows researchers to design and conduct experiments with high flexibility and ease. Its user-friendly interface and advanced capabilities enable scientists and engineers to explore a wide range of material compositions and properties efficiently. The MX-Lab has been adopted by universities and research institutions across 15 countries, leveraging its technology for research and development. Key customers include: - Brown University (USA): Focusing on innovative research in materials science and engineering - University of Michigan (USA): Conducting studies on high-performance alloys and Additive Manufacturing process optimisation - University of North Dakota: (USA): Utilizing MX-Lab for the development of multi-material structures and machine learning applications in Additive Manufacturing - VTT (Finland): Alloy optimisation - COMTES FHT a.s. (Czech Republic): To make a FGM (Functionally Gradient Materials) samples - KAIST (South Korea): To find new compositions of HEA (High Entropy Alloys) An InssTek spokesperson stated, “The high interest and trust in MX-Lab’s performance and potential from research institutions are driving our success in the global market. We aim to continue partnering with more institutions to contribute to innovative technology development.”