Electron Beam Melting EBM is a high technology form additive manufacturing which uses an electron beam instead of a laser or thermal printhead. EBM is often used for the production of incredibly dense metal parts. The material used in electron beam melting is usually a metal powder in pure alloy form (no additional filler material is used in the mixture). EBM begins with a layer of metal powder placed on a temperature controlled print platform. The chamber is vacuum-sealed to minimize any effect of oxidation on the material. The electron beam printer head travels above the powder layer while through electromagnetic coils and melts a cross-sectional area of the object to complete the first layer. The beam is able to rapidly melt areas of the object allowing for faster build speeds compare to other sintering prototyping processes. Once the layer is complete, an automated roller spreads a fresh coat of powder on top of the previous melted layer. The process is repeated until a complete 3D object is formed.
Electron beam melting is used for high stress aerospace applications and medical grade implants. Different titanium alloys as well as cobalt-chrome are used primarily in EBM technique. EBM produces objects that do not require any additional thermal heat treatment to achieve the full mechanical properties of the part. EBM produces parts with solid densities and little to no internal stresses due to the high temperature of electron beam melting. Therefore it allows to produce both prototypes and low cost, high quality parts.
Explaining Video for the process:
Eng. Rami Khalil
Mechanical Design and Production Engineer.