GF Machining Solutions and 3D Systems Forge a Strategic Alliance to Deliver Advanced Metal Additive Manufacturing Solutions

In a significant move to strengthen its footprint in the rapidly evolving metal additive manufacturing market, GF Machining Solutions (GF), a prominent division of the Swiss industrial giant Georg Fischer, has formalized a powerful partnership with leading additive manufacturing innovator, 3D Systems. This strategic collaboration unites GF’s deep-rooted expertise in precision machine tools with 3D Systems’ pioneering advancements in additive manufacturing technologies. The objective is clear: to offer an unparalleled, comprehensive solution for manufacturers worldwide looking to seamlessly integrate metal 3D printing into their production processes and consistently produce high-quality, complex parts.

This alliance is designed to equip manufacturers with an optimized, end-to-end production line. By simplifying the integration of metal additive manufacturing into existing plants, GF and 3D Systems aim to significantly reduce the cost per part, accelerating adoption and unlocking new possibilities for industrial applications. The combined offering addresses critical challenges faced by industries striving for greater efficiency, customization, and design freedom.

The Georg Fischer Group operates across three distinct divisions: the design of advanced pipe systems, the manufacturing of high-performance automotive and aerospace components, and the development of state-of-the-art machine tools utilized across various industrial segments. It is through the latter — its machine tools activity — that the industrial group recognized and committed to the immense potential of metal additive manufacturing. Convinced that AM would revolutionize industrial production, GF embarked on a journey to become a key enabler in this field. The partnership with 3D Systems, established in July 2018, was a pivotal step, leading to the development of a meticulously optimized workflow. This workflow covers the entire production lifecycle, from initial part design and meticulous preparation through to final post-processing, ensuring that manufacturers can effortlessly integrate sophisticated metal 3D printing solutions into their operations.

The inherent complexities of metal 3D printing often require specific design rules and manufacturing protocols that diverge significantly from traditional methods like machining or injection molding. Misunderstandings or misapplications of these rules can lead to design flaws, extended manufacturing times, and inflated costs. This is precisely where the combined strengths of GF Machining Solutions and 3D Systems provide invaluable support, guiding manufacturers through these new paradigms to achieve optimal results.

A Collaborative Vision for Advancing Metal Additive Manufacturing

The strategic alliance between GF Machining Solutions and 3D Systems is built on a shared vision: to democratize industrial metal additive manufacturing by making it more accessible, efficient, and reliable. Dogan Basic, Product Manager at GF Machining Solutions, articulated this vision, stating, “We have witnessed a significant surge in the adoption of additive manufacturing across various industries. We identified a genuine opportunity in leveraging metal technologies to cater to the stringent demands of sectors such as aerospace, medical, and automotive. Our commitment is to provide comprehensive, automated solutions that empower manufacturers throughout their entire production journey. Our partnership with 3D Systems is the tangible manifestation of this commitment, pooling our collective expertise to deliver unparalleled value.” This sentiment underscores the proactive approach both companies are taking to address market needs and drive innovation.

Innovating with Advanced Metal 3D Printers

The core of GF Machining Solutions’ metal additive manufacturing offering revolves around advanced 3D printers, meticulously designed in close collaboration with 3D Systems. These include the DMP Flex 350 and the DMP Factory 500, both built upon the robust and proven Laser Powder Bed Fusion technology, known for its precision and capability in creating intricate metal parts.

The DMP Flex 350 stands out with a generous manufacturing volume of 275 x 275 x 420 mm. This printer is an ideal solution for a diverse range of applications, from the rapid production of finished industrial parts to crucial R&D work requiring high precision. Its compatibility with a broad spectrum of industrial metals and alloys, including resilient steel, lightweight titanium, high-performance nickel alloys, and versatile aluminum, makes it an invaluable asset for various sectors. The Flex 350 also incorporates advanced gas flow technology, ensuring improved and consistent part quality across the entire print area, which is vital for demanding applications.

For larger-scale, continuous industrial production, the DMP Factory 500 represents a leap forward. This modular factory manufacturing solution boasts an impressive build volume of 500 x 500 x 500 mm. It achieves exceptional speed and throughput through its configuration of three powerful 500W lasers, working in unison. The DMP Factory 500 is engineered for true industrial scalability, featuring integrated printer modules and sophisticated powder management modules. These components ensure a highly automated workflow, minimizing human intervention and facilitating continuous, high-volume production, thereby reducing operational costs and maximizing uptime.

Streamlining the Workflow with 3DXpert Software

Both the DMP Flex 350 and DMP Factory 500 are seamlessly integrated with 3DXpert software, a pivotal tool in the metal additive manufacturing ecosystem. 3DXpert is more than just a software platform; it’s a comprehensive solution designed to prepare and optimize 3D printing parts from concept to completion. Its advanced functionalities allow users to manage the intricate creation of support structures and lattice designs, crucial for successful metal prints. Furthermore, it incorporates sophisticated simulation capabilities that enable users to virtually “print” a part before actual production, drastically minimizing potential failure rates and material waste.

The software intelligently proposes the optimal orientation of the part on the build plate, a critical factor for achieving desired mechanical properties and minimizing distortions. It also empowers users to define precise printing strategies tailored to specific material properties and part geometries. Crucially, 3DXpert extends its capabilities beyond printing, seamlessly handling data preparation for any necessary post-machining operations. This holistic approach ensures that, when combined with GF and 3D Systems’ metal 3D printing hardware, 3DXpert automates manufacturing processes, empowers users to create industrial-quality parts with exceptional precision, and significantly shortens time-to-market.

GF Machining Solutions Optimizes the Entire Metal Additive Manufacturing Process

Recognizing the inherent technical and economic challenges that some manufacturers face when adopting metal AM, GF Machining Solutions has engineered an optimized, end-to-end workflow designed to support every user at each critical stage. This comprehensive approach covers: initial part design, meticulous print preparation, the actual 3D printing process, rigorous part inspection, efficient separation of the 3D printed part from the build platform, and crucial post-processing steps. The company leverages not only its advanced AM solutions developed with 3D Systems but also its profound, long-standing expertise in traditional machine tools, offering a truly integrated suite of complementary post-processing and machining solutions.

The Critical Role of Post-Processing and Integrated Solutions

Controlling the entire post-printing process is paramount for the successful adoption of metal additive manufacturing. Without optimized post-processing, this stage can quickly become a bottleneck, consuming considerable time, delaying time-to-market, and escalating overall production costs. This is particularly true for complex metal parts that require pristine surface finishes, precise dimensional accuracy, and careful support removal. Recognizing this, GF Machining Solutions has developed a range of solutions specifically adapted for additive manufacturing, catering to manufacturers who demand continuous production and seek to drastically minimize the time between each print cycle.

A prime example of GF’s innovative post-processing solutions is the CUT AM 500 machine. This specialized system is designed to precisely separate 3D printed parts from their build plates while meticulously preserving their structural integrity and delicate features. The CUT AM 500 utilizes an advanced Electrical Discharge Machining (EDM) process. Unlike conventional cutting methods that involve mechanical force, EDM uses precisely controlled electrical discharges to erode and remove material. In this application, it allows for a clean, stress-free separation of the part from the base plate, preventing damage or distortion that might occur with traditional methods, which is especially critical for intricate or high-value components.

Beyond specialized separation, GF has also developed and integrated other more traditional machining solutions to address the finishing requirements of metal AM parts. Many 3D printed components, particularly those destined for demanding industrial applications, often require additional machining operations to achieve final dimensional tolerances, surface finish, or specific functional features. GF’s extensive expertise in machine tools enables them to provide a holistic solution that covers the entire value chain of metal additive manufacturing, ensuring that parts meet the highest industrial requirements from start to finish. This comprehensive approach underscores GF Machining Solutions’ commitment to providing an unparalleled, integrated ecosystem for industrial metal 3D printing.

Empowering Industries with Integrated Metal AM Solutions

The strategic partnership between GF Machining Solutions and 3D Systems is more than just a collaboration; it’s a commitment to empowering industries to fully leverage the transformative power of metal additive manufacturing. By offering an optimized, end-to-end workflow, from design and printing to advanced post-processing, the alliance provides manufacturers with the tools to innovate faster, reduce production costs, and bring superior products to market. This holistic approach ensures that businesses, particularly those in high-demand sectors like aerospace, medical, and automotive, can seamlessly integrate cutting-edge AM technologies, driving unparalleled efficiency and creating previously unattainable geometries and functionalities.

Looking Ahead: Formnext and Beyond

Manufacturers and industry professionals eager to explore these groundbreaking solutions firsthand are invited to visit Formnext in Frankfurt, scheduled from November 19 to 22. GF Machining Solutions, alongside its invaluable partner 3D Systems, will be present at stand D19/D03 in hall 12.1. This event offers a unique opportunity to engage with experts, witness the latest advancements, and understand how these integrated solutions can transform manufacturing operations. The collaboration between GF and 3D Systems signifies a pivotal moment in the industrialization of metal additive manufacturing, promising a future of greater precision, efficiency, and innovation.

For more detailed information on their advanced manufacturing solutions, please visit the GF Machining Solutions website.

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