Munich-based 3D printer manufacturer EOS recently presented its new 1 kW metal 3D printer M 300-4 at Formnext 2023.
This new system is an updated version of the M 300-4, first introduced at the 2018 International Manufacturing Technology Show (IMTS). It upgrades the four lasers from 400W to 1kW.
These improved lasers were added to meet the production needs of 3D printed aluminum and copper applications. This new system is optimized for the production of high-performance aluminum and copper parts, including brackets, holders, antennas, heat exchangers, inductors and e-mobility components.
While the M 300-4 already has customers in the aviation, medical and energy sectors, it is hoped that the new 1 kW laser variant will open up new applications in mobility and transport.
3D Printing Industry spoke with Sebastian Becker, Head of Metal Systems at EOS, at Formnext to learn more about the company’s latest metal 3D printer.
“The EOS M 300-4 has already proven to be a highly productive AM machine for our customers, but we need to meet the growing market demand for demanding materials such as copper and highly productive processes,” commented Becker. “The EOS M 300-4 1kW delivers performance and productivity with maximum reliability, achieving the lowest cost per part in the industry.”
Sebastiab Becker, Head of Metal Systems at EOS, with the new M 300-4 1kW at Formnext 2023. Photo by 3D Printing Industry.
Optimize costs per part and reduce downtime
The focus of the new M 300-4 1kW is the improved alternator, which increases the four lasers from 400 W to 1 kW. According to Becker, this upgrade was made to address more die casting applications, particularly for aluminum.
“We are currently seeing challenges in aluminum applications, particularly in aviation and the automotive sector,” explains Becker. “That’s why it was important for us to find a solution that offers a really attractive cost per part for aluminum.”
According to Becker, the high productivity of the M 300-4 1kW actually ensures that it is a cost-effective option for metal 3D printing. “The M 300-4 1 kW can 3D print an entire job in 30 to 35 hours. This gives us the opportunity to reduce the cost per part, including operating costs, machine depreciation and consumables such as gas.”
Becker stated that the unit cost for the M 300-4 1kW is just 50 cents per cubic meter, regardless of the application. EOS hopes that this simple solution will make it easier for customers to calculate the cost of their builds. “We want to make these numbers clearer to easily explain to customers what can be done with this technology,” Becker added.
The new EOS M 300-4 1kW at Formnext 2023. Photo by 3D Printing Industry.
Becker also emphasized that reduced downtime is key to EOS’s latest metal 3D printer, especially given the build job. “Once the construction is complete, you want to take it out and get the new one.” To streamline this process, EOS offers the Dual Setup Station.
This station was developed together with the automation system manufacturer Grenzbach and can be used on both M 300-4 and M 400-4 systems to automate the 3D printing exchange process. Process steps such as unpacking the build job and removing residual powder, which are usually carried out while the 3D printer is downtime, can be carried out in parallel with 3D printing.
“The construction job is removed from the process chamber and moved to a parking lot where it can cool. Meanwhile, the second interchangeable frame moves into the process chamber and automatically starts the next job,” explains Becker. This reportedly allows users to achieve a laser-to-laser time (the time between job end and job start) of 30 minutes, significantly reducing downtime.
This level of automation does not come without productivity challenges. “The biggest challenge is that you have to somehow get the speed and heat you put into your role. This cooling time is bad for productivity,” explains Becker.
The key to combating this problem is Smart Fusion, EOS’s proprietary process control software. This platform measures the laser energy absorbed by the powder bed and automatically adjusts it to reduce the temperature where overheating normally occurs.
“Smart Fusion can detect overheating and then we can react to it by controlling the temperature in the melt pool itself,” explains Becker. “This allows us to reduce support structures.” In fact, Becker claimed that Smart Fusion can reduce support structures by up to 95% and enable support-free metal 3D printing, reducing material consumption and shortening post-processing times.
Cold crucible component EOS Copper CuCP 3D printed on the EOS M 300-4 1 kW. Photo by 3D Printing Industry.
Fits into the evolving metal 3D printing industry
The focus on cost efficiency with a small number of lasers certainly sets EOS apart from a number of its competitors in the metal additive manufacturing space.
Becker emphasized that there are currently two clear trends in metal 3D printing. “The industry is moving toward large parts, or it is moving toward making parts cheaper.”
On the one hand, companies are striving to offer larger construction volumes beyond 400 x 400 x 400 mm in order to open up new markets and new applications. Consequently, a larger build space requires more lasers to achieve the required productivity.
As a result, last year saw a “laser war,” with various manufacturers incorporating more and more lasers into more expensive metal 3D printers. Last month, Chinese 3D printer maker Bright Laser Technologies launched the 20-laser BLT-S800, while Chinese counterpart Eplus3D’s new EP-M1550 can integrate up to 25 lasers. Western companies such as Nikon, SLM Solutions and Velo3D are also driving this trend.
According to a market research report from CONTEXT for the second quarter of 2023, these companies are producing more expensive multilaser 3D printers to ensure revenue growth despite lower 3D printer sales. Although powder bed fusion shipments from Western suppliers fell 5% year-on-year in the first half of 2023, sales rose 21%.
EOS Aluminum AISi10Mg Air Cooled Cylinder Heads 3D printed on the EOS M 300-4 1kW. Photo by 3D Printing Industry.
However, the main focus at EOS is “not about having a machine with 20 lasers that costs around $8 million. It’s about having an affordable replacement for die casting applications.” This feeds into the second theme highlighted by Becker a: “Enabling new markets and better business opportunities through better cost per part.” Becker added: “You can’t get a better cost per part by adding 20 lasers. It’s just not possible.”
While EOS’s new M 300-4 1kW clearly fits into the company’s strategic focus of optimizing cost per part, the company’s subsidiary, AMCM, is benefiting from growing demand for large volume builds. The Germany-based company recently launched its latest metal laser beam powder bed fusion (PBF-LB) 3D printer, the AMCM M 8K.
This new 3D printer has eight 1 kW lasers and a significant build volume of 800 x 800 x 1200 mm. The development of the M 8K was supported by a national grant in support of aerospace company ArianeGroup’s Ariane 6 program, a project of the European Space Agency (ESA).
“AMCM is making great progress, we are pursuing the more attractive cost-per-part route,” Becker added.
A large format aerospace part 3D printed on the AMCM M 8K. Photo by 3D Printing Industry
Technical data of the M 300-4 1kW
| Construction volume | 300x300x400mm |
| Laser type | Yb fiber laser; 4 x 400W |
| Precision optics | 4 F-Theta lenses; 4 high speed scanners |
| Scan speed | Up to 7.0 m/s (23 ft/s) |
| Focus diameter | Approx. 100 µm (0.004 inches) |
| Power supply | 3 x 63A |
| power consumption | Max. 19.6 kW / typical 16 kW |
| Compressed air supply | 7,000 hPa; 15 m3/h |
| Dimensions of the 3D printer | 5,221 x 2,680 x 2,340 mm |
| Recommended installation space | Minimum. 8,800 x 5,200 x 3,500 mm |
| software | EOSPRINT 2, EOS ParameterEditor, EOSTATE Monitoring Suite, EOSCONNECT Core, EOSCONNECT Core, EOSCONNECT MachinePark, Materialize Magics Metal Package and Modules. |
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