Requirements_Multi-Laser AM Machine_Final.pdf

Required Specifications

Multi-Laser Metals-Based Powder Bed Fusion Additive Manufacturing System

Background:

Additive manufacturing refers to a class of emerging manufacturing technologies for producing highly-complex, customized components by joining materials to make objects based on three-dimensional (3D) model data, typically built layer upon layer. Parts are fabricated directly from a 3D computer-aided design (CAD) file that is virtually sliced into many thin layers and sent to an additive manufacturing (AM) system where each layer is incrementally formed. Several AM processes and systems have been developed over the past two decades and their capabilities have grown significantly. Generally, metal-based additive processes form parts by melting or sintering material in powder form until all layers are completed.

Additive manufacturing is capable of manufacturing parts that are not possible to make with conventional machining. For example, additively manufactured parts can be fabricated to have highly complex geometries, engineered porosity, and lattice structures. Complex geometries allow components to be designed and built as one part, as opposed to being incorporated in an assembly. Engineered porosity is popularly used in medical or biological applications, because the porous structure promotes osseointegration, the direct structural and functional connection between living bone and the surface of an implant. Lattice structures are popular due to their high strength-to-weight ratios. Another advantage of additive manufacturing is that parts are directly produced from a digital 3D model of the part. This makes the process well suited for the quick manufacture of customized parts. High throughput additive manufacturing builds on these principles with additional considerations such as faster processing times, increased automation, and more streamlined processes achieved through advances in areas such as processing technology, sensor-based process monitoring capabilities, and process modeling and simulation capabilities.

Objectives/Scope:

The purpose of this requirement is to procure one (1) multi-laser powder bed fusion system to be used for the study of high mix/ low volume, high throughput additive manufacturing of metal parts.

Minimum Technical Requirements:

The Contractor shall provide a system that meets all technical specifications identified below. All items shall be new. Used or remanufactured equipment will not be accepted. Experimental, prototype, or custom items will not be considered. The use of “gray market” components that are not authorized for sale in the U.S. by the Contractor will not be accepted. All items shall be shipped in the original manufacturer’s packaging and include all original documentation and software, when applicable.

Size Requirements

The unit, its unassembled components, and the shipping containers must fit through a doorway that is 80 inches high and 64.5 inches wide.

The maximum external height (installed) is 90 inches tall.

The maximum external width (installed) is 60 inches wide, not including door or other accessory components.

The maximum external length (installed) is 100 inches long, not including door or other accessory components.

Laser Requirements

The machine shall use a minimum of four laser beams to locally fuse the powder (i.e., the energy source shall be a minimum of four fiber lasers).

Each fiber laser used to fuse powder shall have full field scanning capability, meaning each laser can reach any point of the build area in its entirety.

The maximum power of each fiber laser used to fuse the powder shall be 500 Watts or higher.

Each fiber laser in the machine shall be supported by dynamic beam focusing capabilities.

Each fiber laser shall have the capability to be operated in either pulse or continuous modes.

Each fiber laser used to fuse the powder shall achieve a minimum spot (focus) diameter at the powder surface of 0.1 mm or smaller.

Each laser beam shall have a maximum programmable scanning speed of 2 m/s or higher.

Build Environment & Monitoring Requirements

The machine shall have an effective building volume (manufactured part size) of at least 245 mm (X) by 245 mm (Y) by 325 mm (Z).

The machine shall incorporate an in-process powder sieving system.

The machine shall have a built-in sensor-based process monitoring capability to characterize the fabrication process in situ.

The machine shall build the part layer by layer from metal powder, with a minimum layer thickness of 0.03 mm or smaller.

Software & Data Access Requirements

The machine software shall allow users to change all process parameters including the powder layer thickness (i.e., open parameter sets).

The machine shall provide open access to all monitored and relevant build data collected during the build.

The machine shall include a process monitoring software package with the ability to monitor and collect process data in real time.

The machine shall support and include dedicated build preparation software with access to open parameter sets.

General and Safety Requirements

The machine shall be a factory-new, commercially available system of the manufacturer’s current design.

The machine shall have a means to automatically fabricate a new part layer on the previously processed layer.

The machine shall be able to manufacture lattice structures and overhang features, e.g., features whose surfaces are supported by unmelted powder during manufacturing.

The machine shall be able to manufacture fully dense (greater than 98%) parts from a variety of metal powders, including reactive materials such as titanium alloys, aluminum alloys, and nonreactive materials such as steel alloys, nickel-based alloys, and cobalt-chrome alloys.

The machine shall be equipped with a PC-based controller that accepts part model data in the Stereolithography (STL) and/or Additive Manufacturing File (AMF) formats through an Ethernet network connection. The controller shall control all machine functions enabling the fully automated manufacture of the part from the supplied part model data.

The machine shall be of a unitized design that allows for ease of installation at various locations or relocation across the NIST campus and shall not require a special foundation.

The machine shall be delivered with powder material to generate test parts out of a nickel alloy and a steel alloy. For each material, the amount of powder shall be equivalent to at least 5 liters of fully dense metal.

The machine shall provide the environment and associated peripherals to build the part in an inert atmosphere.

The machine shall incorporate adequate safety systems for safe operation.

Training:

The contractor shall provide a minimum of 24 hours of training (3 business days) at the NIST facility, for up to 4 personnel. The training shall provide a thorough demonstration of all equipment functions, programming, and operation of the machine controller, machine maintenance, data administration, safety considerations, basic troubleshooting, and all peripherals and post-processing. The training shall include hands-on exercises as part of the instruction. The training shall include electronic and paper copies of training materials and related information, including training handouts, operator manuals, safety manuals, and system maintenance manuals. The training may be completed at NIST immediately after installation/setup and on-site measurements demonstrating that no damage or misalignment issues developed during transportation and installation (as described below), but shall be completed no later than 30 days calendar days after installation.

Delivery and Installation:

Delivery shall be FOB destination and shall be delivered within 4 Months after award.

The contractor shall deliver, install, and test the machine at the NIST campus in Gaithersburg, MD in an existing building space to be identified by the Contracting Officer’s Representative (COR). Any factory recommended foundation requirements shall be the responsibility of the contractor. All transportation, rigging, and setup (unpacking, positioning, and leveling) are the sole responsibility of the contractor.

Acceptance:

The contractor shall test the integrated system and demonstrate its ability to meet the minimum technical specifications. All required instrumentation, powder materials, and tooling required for testing are the responsibility of the contractor. The tests shall be conducted before shipping the machine to the government and after installation of the machine at NIST. The tests will be reviewed and verified by the NIST Contracting Officer’s Representative prior to acceptance. NIST reserves the right to independently test the installed system before acceptance for a period not exceeding 14 business days.

Warranty and System Maintenance:

The entire machine, including all mechanical, electrical, electronic, optical, and software components, shall be warranted for a minimum period of one year. All parts, labor, travel, expenses, etc., to repair any machine component shall be provided by the manufacturer at no additional cost to the Government during the warranty period. The contractor shall provide a warranty for one year to resolve any latent equipment problems discovered. The contractor shall provide one preventive maintenance visit six months after award to ensure the equipment is functioning properly.

Deliverable Due Date Recipient Approval Product Delivery 4 Months After Receipt of

Order

COR

Product Installation Within 30 Days After Delivery

COR

Product Training Within 30 Days After Installation

COR

Maintenance Visit Within 6 Months After Installation

COR

Contract Type:

Firm Fixed Price