Nikon has realized additive manufacturing using a laser with the concept “using light to see and light as a tool”. This section explains the merits of Nikon’s metal 3D printer.

Nikon’s metal 3D printer employs the laser metal deposition (LMD) method that builds up layers by melting the metal and depositing metal powder onto that part. A feature of this method is that additive manufacturing can be performed on existing parts. In addition to metal modeling from scratch, with its ability to perform tasks such as adding new functionality to existing parts and performing precise repairs, this machine expands the possibilities of metal modeling.

Nikon’s metal 3D printer employs a 5-axis mechanism. This 5-axis mechanism is composed of a 3-axis mechanism with the three axes X, Y and Z and a 2-axis rotation mechanism with an axis that rotates like a potter’s wheel and an axis that tilts like a swing. The 5-axis mechanism is employed to enable modeling with a high level of flexibility.

Measuring cameras are installed inside the machine and the position etc. of the workpiece is acquired automatically by making full use of the measuring and ranging technologies Nikon has cultivated over many years. High precision alignment measurement (three-dimensional shape measurement by analyzing the time difference and irradiation angle when the light beam hits the object and is reflected) is performed on the workpiece by scanning it through 360 degrees from all directions.

This means that the positioning (setup) manually performed by a skilled worker in an ordinary metal 3D printer can now be performed easily by anyone, realizing ease of use and reduced man-hours.

The state of melting in the metal melt pool is monitored and modeling operation is controlled to stabilize the modeling shape. This control achieves uniform shapes at edge areas where the heat dissipation differs, eliminating the generation of protrusions.
In addition, to improve modeling quality a powder supply feedback function is installed on the machine that observes the powder at high speed and controls the powder supply operation when powder is being supplied.

The modeling surface shown on the left with no melt pool monitoring is rough and uneven whereas with control by melt pool monitoring as shown on the right the top and peripheral parts of the modeling surface are stable and smooth modeling can be performed.

Extremely versatile stainless steel, high speed steel usable as a material for tools capable of scraping metal at high speed, nickel-base alloys that are industrial materials with excellent corrosion and heat resistance, and titanium alloys that are used in various industries because they are light, strong and do not rust.
The ability to use these materials makes it possible to meet a wide range of needs in various industries including the machine processing, medical, and aerospace industries.

The results of internal void inspection on an SUS 316L grade stainless steel 10 mm square cube modeled using standard modeling conditions is shown below. No voids (air bubbles, small cavities) are observed inside modeled object, indicating that it has no defects.

The following data shows the results of tensile strength testing that conforms to the JIS standard of objects modeled from SUS 316L grade stainless steel. Inspection is performed five times each for items modeled in the horizontal direction and items modeled in the vertical direction. As you can see, both guarantee strength that exceeds the reference value.