Efficient AM for F1

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Efficient powder handling is the key to more productive metal additive manufacturing of F1 components at Progressive Technology.

Progressive Technology uses CNC multi-axis machining and additive manufacturing (AM) to manufacture complex metallic components, primarily for the Formula One market.

Steve Shadwell, Manufacturing Manager at Progressive Technology, said, “We initially entered the F1 market manufacturing low-tech products, and have steadily progressed to where we are today – creating very high-end componentry and servicing most of the teams on the F1 grid. Since our expansion four years ago, we set out three key objectives; to invest and continually develop our machinery and production facilities; to employ and train highly skilled engineers; and to provide a full 24/7 manufacturing facility to meet the needs of our customers.”

After initially entering the F1 market manufacturing low-tech products, Progressive Technology has trebled its turnover in the last four years and is now creating high-end componentry and servicing most of the teams on the F1 grid. A full 24-hour shift pattern allows rapid turnaround of parts, and the company invests in the highest quality equipment to optimize its production process. This is reflected in its additive manufacturing facility, where Progressive Technology continues to invest in the latest production technology, ancillary equipment and materials to ensure a high-quality product in minimal time.

Laser powder bed fusion technology has been chosen by Progressive Technology and provides significant benefits when producing F1 components such as increasing strength and the R&D time required to produce new designs with the biggest benefit coming from weight reduction.

A key part of this additive manufacturing process is the handling of the powders used to produce the parts. Metal powders such as titanium, aluminium and Inconel are commonly used to produce the parts for F1 cars and therefore to ensure their quality, the powder must be qualified before use and after the build process is complete the unused powder is reclaimed and requalified.

Initially, the method used to process the metal AM powder was very time consuming with high product wastage. Now, Progressive Technology uses and automated system the Russell AMPro Sieve Station.

Printer processing times can take an average of 20 hours to complete, and therefore it is imperative production downtime is kept to a minimum. With the installation of the Russell AMPro Sieve Station, Progressive Technology has been able to double productivity with only half the labour previously used.

The strength of the Russell AMPro Sieve Station is that every detail has been designed and incorporated into one system resulting in a fully-automated process. An intuitive interactive user interface brings together all elements of the system and allows for a fully programmable one touch operation which minimizes operator involvement. The system is completely modular, designed to integrate directly into an existing build process within DMLS, LMD, SLM, SLS and EBM systems.  

http://progressive-technology.co.uk/

www.russellfinex.com

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