GF Machining Solutions: Pioneering Metal Additive Manufacturing for Industrial Serial Production with Integrated Workflows

In recent years, the landscape of industrial manufacturing has been significantly reshaped by the remarkable growth of metal additive manufacturing. This revolutionary technology, often referred to as metal 3D printing, has rapidly gained a central position within the global 3D technology market. We’ve witnessed a surge in the number of machine manufacturers, the development of increasingly stronger alloys and advanced materials, and the emergence of sophisticated software solutions that streamline and optimize the entire design-to-production process. The overarching goal behind these advancements is clear: to democratize the use of metal AM, making it more accessible and practical for a wider range of industries. This also involves equipping companies with reliable and sustainable technology, frequently integrating it as a powerful complement to their existing subtractive manufacturing solutions.

This transformative mission lies at the heart of GF Machining Solutions, a key division of the renowned Swiss industrial group, Georg Fischer. GF Machining Solutions embarked on its journey into metal additive manufacturing several years ago, recognizing its immense potential. Since then, the company has dedicated significant resources to develop and optimize an entire value chain for metal AM. Their expertise now spans every critical stage of manufacturing, from initial design and robust printing processes to essential post-processing techniques. To delve deeper into GF Machining Solutions’ strategic vision, their commitment to advanced manufacturing, and their exciting future projects, we had the distinct pleasure of speaking with Ralf Loettgen, the Head of Additive Technologies at GF Machining Solutions.

3DN: Can you introduce yourself and explain your connection to additive manufacturing?

Hello, I’m Ralf Loettgen, and I serve as the Head of Additive Technologies. This department is an integral part of GF Machining Solutions’ Business Unit dedicated to ‘Advanced Manufacturing.’ My journey with GF Machining Solutions began way back in 1993, giving me the unique opportunity to immerse myself in the company’s extensive portfolio of machining technologies. Over the years, this has allowed me to gain invaluable experience across various disciplines, starting with Electric Discharge Machining (EDM), then transitioning into high-speed and high-performance milling, and subsequently, automation solutions. I also played a significant role in overseeing the production of spindles at Step-Tec, which is another specialized area of our operations. Then, in 2015, a new and exciting chapter began as I took on the responsibility for additive manufacturing. Having closely monitored the progression of this technology for quite some time, it felt like a natural and compelling next step for me to accept the challenge of integrating additive manufacturing into GF Machining Solutions when the opportunity arose a few years ago. It has been a fascinating and rewarding endeavor to contribute to the growth of this innovative field within our well-established company.

3DN: Why did GF decide to get into additive manufacturing?

GF Machining Solutions has been closely monitoring the significant developments in metal additive manufacturing for over 15 years. This long-term observation was strategic. When we rebranded our company from Agie Charmilles to GF Machining Solutions in 2013, we recognized a critical need to encompass this emerging technology within our offerings. Our strategic conclusion was that to truly provide the most comprehensive and effective end-to-end solutions to our valued customers, integrating additive manufacturing was essential. We hold a strong conviction that while additive manufacturing will not entirely replace conventional machining technologies, an increasing number of industrial applications will undoubtedly incorporate AM into their processes in the future. The synergy between these technologies, rather than outright substitution, is what drives our strategy.

Furthermore, our extensive and deep-rooted experience in both subtractive and now additive manufacturing places us in a unique position. This expertise allows us to actively contribute to the ongoing development and maturation of this relatively young yet rapidly evolving technology. This is particularly relevant given that additive manufacturing has now progressed beyond prototyping and entered the crucial stage of serial production. Achieving serial production always necessitates a precise combination of different manufacturing steps, and metal additive manufacturing perfectly complements our broad and sophisticated technology portfolio. This includes our renowned milling and EDM machines, as well as cutting-edge solutions for laser texturing, laser micromachining, and advanced automation systems. Our entry into metal AM was not merely opportunistic; it was a carefully calculated strategic move to enhance our ability to deliver holistic, cutting-edge solutions.

Given our goal of integrating, rather than reinventing, core AM technology, we actively sought out the best possible partner. We needed a collaborator who possessed profound experience and could contribute significantly to the fundamental aspects of metal additive manufacturing. After a thorough evaluation and rigorous testing of various options, we concluded that 3D Systems was the ideal technology partner for GF Machining Solutions. Our respective capabilities and competencies complement each other exceptionally well, and crucially, we share an identical vision: to prepare additive manufacturing for robust and reliable serial production. This strong alignment led to the official communication of our strategic partnership in the summer of 2018, followed by the impressive unveiling of our first joint solution at IMTS in Chicago in September 2018. This collaboration represents a powerful synergy, combining GF’s precision machining prowess with 3D Systems’ leadership in additive technology.

3DN: Manufacturing can often be complex, what help do you offer to your clients?

The inherent complexity within modern manufacturing processes is precisely where GF Machining Solutions, in collaboration with 3D Systems, excels at simplifying operations for our clients. Historically, pioneering efforts in additive manufacturing achieved remarkable feats, enabling the creation of fantastic part geometries with attributes like significant weight reduction, unparalleled design freedom, and the integration of novel functionalities. However, the user was often left to navigate the challenging subsequent steps required to transform a printed part into a fully functional component ready for industrial application. This frequently included the intricate task of integrating the printed part into larger assemblies such as molds, engines, or even into the human body for medical implants. Our philosophy dictates that the optimal solution can only be discovered by considering the *entire* value chain, from the initial concept and design stages right through to the final finished product.

GF Machining Solutions, with its unique and comprehensive technology portfolio and extensive application experience, combined with 3D Systems’ position as a leading innovator in additive manufacturing, collectively possess the potential to deliver truly unique solutions. These solutions are meticulously designed to optimize the workflow across multiple, interconnected process steps. Our approach extends beyond mere physical processes; it meticulously integrates the digital dimension as well. This holistic, global perspective profoundly influences the development of intuitive interfaces between different systems and is continuously enriched by the active exchange of knowledge among experts representing various machining technologies. Our commitment is to provide a seamless, integrated manufacturing experience that addresses both the physical production challenges and the digital workflow requirements.

Furthermore, to provide specialized support, 3D Systems operates its Customer Innovation Centers, while GF Machining Solutions established its dedicated AMotion Center. These centers are strategically focused on developing highly tailored production processes. These bespoke processes are designed to address the specific and often unique requirements of various industrial segments, including critical sectors such as medical devices, aeronautics and aerospace components, intricate mold and die production, and general industrial parts manufacturing. Beyond development, the robust global and local organization of GF Machining Solutions ensures comprehensive after-sales service and expert application support across the entire globe. Our dedicated teams are always ready to assist customers, ensuring their equipment operates at peak productive levels and sharing invaluable application knowledge to help them maximize their investment and capabilities.

3DN: Why did you choose to focus on metals? What are the key applications of your machines?

Our decision to focus specifically on metal additive manufacturing is rooted in our core expertise and strategic alignment. If you consider the entire part production value chain, it becomes evident that plastic and metal parts typically diverge significantly in their manufacturing processes, material properties, and end-use applications. Since GF Machining Solutions’ product portfolio has historically and consistently been centered on advanced subtractive manufacturing technologies designed for metal parts, the integration of metal 3D printing was a perfectly logical and synergistic addition to our offerings. This strategic choice allows us to leverage our deep-seated knowledge of metallurgy, machining, and industrial applications for metal components. By focusing on metals, we can truly add substantial value to the entire production process. We are uniquely positioned to support our existing customer base throughout their complete journey, from the initial design phase through the precision printing and subsequent machining stages, all the way to the delivery of a meticulously finished, high-performance metal component. Our machines find key applications in demanding industries requiring high precision, complex geometries, and superior material properties, such as aerospace for lightweight structural components, medical for customized implants and surgical tools, and mold & die for conformal cooling channels to enhance efficiency.

3DN: How do you see AM co-existing with traditional manufacturing methods?

We firmly believe that there is no genuine competition between additive and subtractive technologies; rather, they are inherently complementary. These two distinct manufacturing paradigms are destined to co-exist and, indeed, profoundly influence each other in a synergistic relationship. To achieve true cost-effectiveness and deliver components with precisely defined characteristics in terms of accuracy, surface finish, and structural integrity, additive manufacturing – despite its immense potential to generate additional value through design freedom and complexity – will invariably require the application of subtractive manufacturing technologies. These traditional methods are crucial for both the preparation of printed parts (e.g., base plate removal, stress relief machining) and, more importantly, for the finishing processes that ensure the component meets exact specifications for fit, form, and function.

However, it’s vital to recognize that a part initially printed very close to its final net shape will present significantly different requirements for subsequent subtractive manufacturing compared to starting with a raw, square block of material. This concept is not entirely novel; for instance, forged or cast parts have historically provided a similar ‘near-net-shape’ starting point for traditional subtractive processes, minimizing material waste and machining time. We are absolutely confident that additive manufacturing is a game-changer. It will evolve into an indispensable tool for developing the most optimal applications in the most cost-efficient manner possible. The key lies in recognizing and actively developing these powerful technology synergies. This involves creating smart, seamless physical and digital interfaces that facilitate a streamlined workflow along the entire manufacturing process chain. This optimization includes providing individual parts with consistent references and clear identification throughout their journey, ensuring traceability and precision in every step from design to final inspection. This integrated approach, often termed hybrid manufacturing, unlocks unprecedented levels of efficiency and innovation.

3DN: What are your future projects?

At Formnext 2019, visitors to the joint booth of GF Machining Solutions and 3D Systems had the unique opportunity to experience firsthand the strategic vision shared by both companies. This vision is centered on the seamless integration of metal additive manufacturing into robust industrial serial production processes. Achieving this ambitious goal necessitates a comprehensive, holistic approach that considers the entire end-to-end process, meticulously planned from the very first stages of design for additive all the way through to the shipping of the final validated part. Our future projects will unequivocally maintain a sharp focus on refining and expanding this integrated end-to-end workflow. We are committed to developing innovative new approaches that will significantly reduce overall production costs. This will be accomplished through the seamless integration of both physical manufacturing processes and sophisticated software workflows, crucially including advanced inspection procedures at every critical juncture. By ensuring digital continuity and physical precision, we aim to deliver unparalleled efficiency and reliability in additive manufacturing for our customers.

3DN: Any last words for our readers?

Additive manufacturing is undeniably an exciting and stimulating field, offering immense possibilities for innovation. However, at its core, it must consistently generate tangible additional value for businesses and industries. This crucial value proposition can only be accurately and comprehensively assessed when we consider the entire journey, from raw material to a fully finished part that is genuinely ready for its intended use. This holistic perspective, looking at the process from end-to-end, is not merely advantageous; it is absolutely mandatory. Ultimately, this comprehensive evaluation will be the decisive factor in determining the feasibility and success of any business case involving additive manufacturing. It’s about delivering real-world solutions that are both innovative and economically viable.

For more detailed information on our advanced manufacturing solutions and our commitment to metal additive manufacturing, please visit the GF Machining Solutions website.

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