Enigma CML Hybrid Multi-Laser Coaxial Composite 3D Printing Technology: Paving the Way for DED Intelligence and Automation

PanDen 2024-9-19 23:09 3D Printers

Nanjing Enigma Industrial Automation Technology Co., Ltd.( 南京英尼格玛工业自动化技术有限公司) is rapidly emerging as a technical pioneer in the industry, thanks to its innovative additive manufacturing and intelligent welding solutions. This year, the company has launched several groundbreaking devices and technologies, most notably its mobile robotic additive system. This system, integrating automation and intelligence, breaks the constraints of traditional fixed 3D printing equipment, significantly boosting the production efficiency of large-scale components.

In addition, Enigma has introduced multi-laser coaxial composite additive technology, intelligent additive software, and a comprehensive quality monitoring system, further showcasing its deep expertise and technological leadership in the field of Directed Energy Deposition (DED) technology.

The Mobile Additive System Overcomes Spatial Limitations, Meets Large Component Production Needs with Flexibility

At the 2024 Formnext Shenzhen Expo, Zhao Lupeng, an Enigma representative, introduced to Panda3dp.com the company’s flagship product at the exhibition—the mobile robotic additive system. This highly flexible system, using an AGV mobile platform as its base, can move the equipment directly to the component that requires processing, enabling intelligent welding and additive manufacturing. Unlike traditional fixed 3D printers, Enigma’s mobile system does not require transporting workpieces to a designated work area. Instead, the equipment actively seeks out the component, enabling on-site manufacturing for large-scale workpieces.

Zhao Lupeng explained: “This system is particularly suited for large components. Traditional methods often require the workpiece to be moved to a fixed device, while our mobile robot can reach the workpiece’s location, greatly enhancing production efficiency.” The system also features a lifting mechanism and an advanced laser scanning camera. By scanning and generating a 3D model of the workpiece, intelligent software automatically plans the additive path and issues instructions, facilitating fully automated operations.

The equipment surpasses the limitations of the XY-axis; as long as the workshop space is adequate, the robot can perform additive manufacturing at any location. This breakthrough resolves the size constraints imposed by traditional equipment, providing a novel solution for complex and large-scale manufacturing projects.

A Comprehensive Additive Manufacturing Solution From Materials to Equipment

Enigma not only supplies additive manufacturing equipment but also offers a full suite of solutions in materials, software, and quality monitoring. Zhao particularly emphasized the company’s melt pool monitoring camera, which can provide real-time observation of the melt pool during laser and arc processes, making it an indispensable tool for ensuring stability during additive manufacturing.

As a provider of Directed Energy Deposition (DED) solutions, Enigma’s offerings span from material development and equipment design to process realization, forming a closed-loop system developed entirely in-house. Zhao highlighted the company’s emphasis on material stability and composition control during the development of wire materials for additive manufacturing. To ensure these materials are suitable for additive manufacturing, they undergo rigorous mechanical testing and microstructure analysis, which helps address anisotropy issues, guaranteeing the quality and performance of additive-manufactured components. This meticulous attention to material quality reflects Enigma’s rigorous approach to technical details.

This comprehensive solution, spanning from materials to equipment, showcases Enigma’s deep technical expertise and control over the entire additive manufacturing process chain.

CML Hybrid Multi-Laser Coaxial Composite Technology Enhances Manufacturing Flexibility

Zhao also introduced the company’s latest hardware system launched this year—the CML-Hybrid-1500DF-ARC multi-laser arc coaxial composite system, which incorporates CML Hybrid technology. This system integrates all DED processes, utilizing six independently adjustable laser modules combined with arc heat sources, six channels for simultaneous powder and wire feed, and dual-channel shielding gas. It achieves four composite processes: multi-wavelength laser fusion, laser-arc fusion, wire-powder fusion, and shielding gas fusion. The system is designed for advanced research areas such as gradient materials with varying compositions, in-situ alloying, high-throughput material preparation, and microstructure control in DED technology. At the same time, it meets the engineering applications required to enhance additive material compatibility, efficiency, component precision, performance, and complexity. It stands as the pinnacle of DED technology integration.The system’s key feature is its ability to switch between multiple protection modes and processing techniques, catering to various material and process requirements.

Coaxial Multi-Laser Hybrid (CML Hybrid) is based on the multi-beam integrated coaxial laser directed energy deposition technology (CML) which is developed by Enigma in collaboration with Nanjing University of Science and Technology and incorporates 13 years of expertise Enigma has gained in the field of arc additive manufacturing since its inception. This collaboration marks a pioneering advancement in the development of new DED technology worldwide.

This new multi-functional composite technology greatly expands the equipment’s range of applications, addressing both experimental research and production needs, marking a significant breakthrough in the field of additive manufacturing.

Intelligence and Digitization Drive Full Automation

Enigma’s products excel not only in hardware but also leverage software and digital tools to enhance overall production efficiency. Zhao explained that the company’s intelligent additive software can automatically complete the entire additive manufacturing process through model import, path planning, and simulation steps. This automated process requires no human intervention, significantly reducing operational complexity and increasing production efficiency.

Additionally, the company has developed a process quality monitoring system that can monitor key parameters such as the internal printing state, temperature, humidity, and melt pool morphology in real-time. The system is also equipped with a trace-back function, allowing operators to review and analyze any issues that arise during printing. This intelligent system plays a crucial role in improving product quality and optimizing production processes.

Zhao noted: “With this software system, we can monitor every detail of the production process in real time, ensuring printing precision and efficiency. This is especially important for automated production, as it greatly reduces human error.”

Forward-Looking Technology and Applications: The Wide Prospects of DED

In addition to optimizing existing technologies, Enigma is actively exploring cutting-edge applications of additive manufacturing. For example, in the construction and civil engineering sectors, Enigma has provided test pieces for large components to customers, verifying their shape accuracy and mechanical properties. These applications demonstrate the immense potential of additive manufacturing technology in traditional industries.

Furthermore, Enigma’s “MaxFeed Digital Large Wire Feeding Module” solution is another of its major innovations in the field of additive manufacturing. This device can accommodate more wire materials, ensuring continuity and stability when printing large components. Particularly for highly oxidative materials, the module is equipped with temperature and humidity control to further ensure print quality.

Conclusion

At this year’s Formnext Expo, Enigma demonstrated its comprehensive strength in the fields of additive manufacturing and intelligent welding. From mobile robotic additive systems to multi-laser coaxial composite technology and an all-encompassing digital monitoring system, Enigma is advancing the manufacturing industry toward a future of intelligence and automation. As DED technology continues to mature, Enigma will showcase its technological edge in a broader range of fields, delivering transformative changes to the industry.

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