3D Metal Printer System

Active

Contract Opportunity

BACKGROUND

The Air Force Research Laboratory (AFRL) in Rome, NY is seeking information from sources that may be capable of providing a commercial product solution that meets or exceeds the following draft minimum specifications.

Below is a description for minimal requirements for a system which includes the build chamber, laser system, gas handling, software for controlling and monitoring the system as well as importing CAD drawings, metal powder storage and reclamation, support and training, and materials parameters among other subsystems. Critically, this system should be capable of producing parts made out of invar and AlSi10Mg, along with stainless steels, tool steels, cobalt chrome, aluminum, inconel, and titanium. For invar, the vendor MUST have parameters developed for creating parts “out of the box.”

Incomplete systems not containing all components and all capabilities described below do not meet minimum requirements.

1). Twin Laser system with Invar Beta Parameters

QTY = 1

-Selective Laser Melting machine

- build envelope of 280 x 280 x 350 mm or larger

-adjustable layer thickness 20 - 120 microns or finer

-max print speed > 50 cm^3/hr or faster

-laser focus diameter: adjustable 80 – 115 microns or wider range

-Twin lasers, at least 700W for fast printing to achieve 50 cm^3/hr

-”air knife” system to create laminar flow of inert gas over optics entering build chamber to prevent damage to optical elements

-bi-directional powder recoating

-open software architecture with the freedom to control system parameters

-Layer control system,

-Laser Power (LPM) monitoring

-Melt Pool (MPM) Monitoring

-supplied external water/water or water/air cooling system

Must containing the following operational basic configuration:

-Laser and Optical Bench

-Coating System & Main Tank

-Process Gas Filtration

-Electronics, Control Computer, and Machine Software (MCS)

-Process Build Chamber

-Layer Control System (LCS)

-Platform Mechanism

-Air Treatment

Optical Bench

Laser system: optical bench within a sealed housing optics against dust and vapors. Housing should be overpressured with continuously supplied clean dry air necessary for continued operation of the high power laser used for powder bed fusion.

Laser alignment on the powder bed should be digitally controlled with a galvo system.

Water-cooled 3D scanning alignment system should be used to direct the laser onto the powder bed additive manufacturing area. Optics should maintain system reliability and accuracy (see below)

AM process chamber

-ergonomic accessibility to ensure ease of access for loading, component removal, and cleaning.

-clear view of chamber and printing process using laser safety glass. Lighting system to view the parts during production and in detection system to detect process problems during production.

-chamber design should minimize inert gas consumption during chamber flooding and normal operation

-gas tight gloves to allow manipulation of the part and removal of excess powder under an inert environment.

-exhaust air should go through H13 class filters or better to purify air before venting into exhaust system

-feedthroughs for data and supply lines for process customization and monitoring during production

Recoater system

-multidirectional coating system required, bi directional acceptable

-powder must be deposited on both forward and backward movements minimally

-after layer deposition, system must operate without going to home position before applying new layer (to speed up manufacturing process)

-coating guide system must be dustproof

-soft leveling blades must be available

-powder recovery system must recover unused powder so that it can be re-used in the process

-at least two valves between powder handling system to prevent powder contamination and oxidation

Materials and Process Parameters

-diverse set of materials and parameters should be available from the manufacturer. The following materials represent a minimal set: invar, stainless steels, tool steels, cobalt chrome, aluminum, inconel, titanium, AlSi10Mg.

-system must also include material development options to develop custom materials and processes not listed above

Laser Control System

-system must monitor build process, and detect and respond to build irregularities such as recoating an area or halting the process. Identification of irregularities should be coded in by setting thresholds in software

-LCS should also allow manual intervention in a process

-LCS should document each layer in the build as a record and for evaluation of the process as new materials are utilized

-LCS system should process high quality images of build:

Process Gas Filtration

-powder bed fusion system must operate in an inert environment (ex: argon, N2) with enough gas flow to maintain print quality by regulating temperature and soot removal

-gas flow sensor

-minimum two oxygen sensors

-minimum two temperature sensors

-dew point sensor records gas dew points throughout process

-compressor to generate volumetric gas flow that can be set and monitored for printing. Must have automatic control system

-oxygen sensors must detect oxygen at the part per million level

-temperature sensor and internal gas and water heat exchanger to regulate temperature and maintain gas flow

-gas system must minimally have two large main filters, along with an additional fine filter in series. Filtered gas should then be recirculated into the process chamber to minimize particle concentration in the gas flow.

-For safe filter removal, a double valve should be used for all interfaces between the system and filter housings and in powder handling.

-filler flushing device: inert gas is slowly replaced by water during removal of the filter to reduce

the risk of oxygen reactions.

-Main filters should be located outside the machine and easily accessible for replacement.

-The long-life fine filter should be housed in the machine cabinet but should still be accessible

-process gas filtration must be upgradeable so that filters can be hot-swapped into system during a paused build process

Platform Mechanism

-365 mm precision travel in z-direction (transverse to build plane) for large objects

-heating element to increase substrate temperature by up to 200 C. Dedicated control circuit should maintain set and adjust the temperature throughout the process

Electrical requirements

-electrical and control system components housed separately from gas and water supply

-safety interlock to prevent access to electrical system while machine is in operation

-should be compliant with NRTL machine safety regulations in North America.

-network connection for updating software and remote customer service

Machine control system

-machine control software must be compatible with Windows 10 or newer computer

-all machine functions should be accessible via control software during operation and during paused operation.

-software must display relevant parameters during build such as: build time, time remaining, temp, oxygen content, filter status, etc.

-software must store relevant process data to allow for post build analysis, data documentation for research, and machine statuses and parameters. System should be capable of sending data at user request to vendor for analysis

-should be capable of producing a report documenting powder type, slicing parameters, machine settings, pictures of the build process, tensile test results, density test results, and roughness measurement results

Lasers:

-dual water cooled lasers with output optical power of at least 700W to achieve >50 cm^3/hr print speed

-on axis measurement system to track target and actual laser output power during build process, software to identify deviations

-measurements must occur on both beams, documented in software

Melt Pool Monitoring

-system must measure and create visualization for melt pool by recording thermal radiation from the melting powder bed fusion process

-measurement must be approximately on axis, measured by photodiodes

-measurement bandwidth should be capable of reaching 100 kHz minimum

-each laser beam should have independent melt pool monitoring system

-photodiodes should record two different wavelength ranges

Additional software requirements:

-Desktop program to access, visualize, analyze, and export build data and parameters

-dashboard to record build job, warnings and errors, process condition parameters,

-production and quality reporting tool for individual builds

-python compatibility for analysis of machine and build parameters

Installation and training

-operator and applications training in full operation of AM metal system for relevant personnel (see description below)

Vendor Support

-vendor must be able to provide on-site maintenance services

-latest parameters for metals should be delivered with machine

-vendor should have training materials available for continued learning

2). Installation service

QTY = 1

1 year warranty, freight, machine installation package, starter package tools

and accessories, chiller (air to water), chiller installation package, and transformer

3). Powder sieving machine (PSM)

QTY = 1

PSM unit to sieve and separate metal powder under inert gas conditions. Metal

powder collected from overflow cans in the selective laser melting system is manually

supplied to the sieving station.

Powder sieving machine

-standalone unit

-ultrasonic transducer parameters should be adjustable for noise considerations and induced mechanical vibrations that could affect other equipment in the vicinity

-system should be operated under inert gas with oxygen content monitored as described above.

-sieve unit and pipework should be changeable to accommodate changes in materials.

-metal powder should be sieved into a container which has a closing valve, ready for re-use.

-particles that are too large should automatically be directed into a separate container.

4). Chiller Package Air/Water (NRTL)

QTY = 1

Chiller for cooling heat sensitive components of machine

5). Micro blasting

QTY = 1

Machine must prepare AM metal parts and must have the following capabilities: surface cleaning (remove hard and carbonized hard oxides), surface structuring, shot peening, deburring, and preparation of adhesive surfaces.

The machine must meet the following characteristics:

-stroke flap front door linked to gas cylinders that can be opened to working height of microblasting equipment. Door switch interruptor

-sight window with double pane glass (2 layers: safety and attrition-proof)

-hydraulic lifting mechanism, two column, for manual adjustment of part height

-wheels with lock for moving machine

-drying system for microblasting agent, at least 120W heating

-padded sleeves and gloves, replaceable after inevitable wear

-microblasting pistol unit with hard metal blasting nozzle:HSD 5/10. Contains control system, pressure reduction valve and manometer (0 - 10 bar)

-microblasting agent pre-acceleration unit with moving injector unit, control system with setting range 0 - 4 bar minimally, manometer and pressure reduction valve

-auto fine-grain size separation system

-blow-out pistol

-foot-actuated switch with impulse mode

-compressed air connection at system with oil and water separator

-control panel with key operation switch, to control necessary components,

-ventilator for microfilter unit

-built-in surface microfilter system

6). Build Volume Reduction to 100x100x170 mm3 or smaller

QTY = 1

-adapter system for reduced sized platform with 100mm x 100mm x 170mm or smaller build envelope.

-can be integrated into the system and removed with a few simple steps.

7). High Temperature Heating Module

QTY = 1

-high temperature heating system: modular design for mounting on machines.

-accommodates geometries with component heights up to 100mm

-Extend substrate heating temps to above 550 C

8). Adjustment tool for layer preparation

QTY = 1

-Tool used to adjust the recoater for the proper layer thickness.

-machine should include an adjustment tool to set the soft-tipped recoating tip to allow for operation between overlap areas of part builds.

-adjustment tool should be a substitute / replacement for service visits to manage overlap areas

9). Handling Devices electric lift and bottle lift

QTY = 1

A combination tool consisting of the electric lift used to unpack substrate plates from the machine, and a powder bottle attachment used to reduce heavy lifting by personnel loading powder into the machine.

10). Safety Vacuum Cleaner for metal powder (Ruwac MX361)

QTY = 1

Explosion proof industrial vacuum system. Must have the following characteristics:

-150 CFM

-Primary Filter Type: HYDROPHOBIC & OLEOPHOBIC CARTRIDGE

-Collection Capacity (gallons): 12 Gallon Immersion Tank minimum

-Vacuum Inlet: 2 Inch ID Aluminum Cast Inlet

-must meet all regulations for removal of metal powder including aluminum and steels

11). Powder Bottle 5L (with flap valve)

QTY = 6

5L (min volume) powder bottle for safely storing metal

12). Holder for Recoater Brush

QTY = 1

Adapts the recoater to work with brushes rather than the standard rubber recoater

lips. Two brushes required.

13). Recoater

QTY = 1

Extra recoater for faster material change.

14). Recoater Brush

QTY = 4

Alternative to rubber recoater lips.

15). PFM Steel Bucket 20L (with cover)

QTY = 20

Bucket 20L (min volume) tin w/cover and clamping ring for disposing powder fusion metal

16). PFM Precoat Material (4x 3kg)

QTY = 16

Precoat material provided in 4X3kg packages

17). Substrate Plate for printer (Stainless Steel, 30mm, 4xM5)

QTY = 6

substrate plate with M5 bolts and slots for build plate handling device

18). Fe-Alloy Invar36 10-45μm, 10kg unit, 120Kg total,

QTY = 12 packages, each 10 kg

-Invar 36 alloy powder size must be compatible with 3D AM system, can be used in conjunction with laser parameters in the system to print parts out of invar.

19). Material Change Kit for AM machine

QTY = 1

Components for a fast material change on a tank fed version, including powder tank, and recoater.

20). Material Change Kit for sieving machine

QTY = 1

Sieving channel for quick material change

21). Moisture Meter for Powder

QTY = 1

Tool used to measure moisture level in powder.

22). Powder Flowmeter Part

QTY = 1

Measure powder consumption during build process

23). Fixed license software to do the following (Materialise Magics)

QTY = 1

-Combines the build preparation tools and file generation technology to repair and edit files, prepare the build platform and process slices .

-fixed license to import 3D CAD files and convert them to SLM files necessary to operate machine

-should support IGS, DXF, ST, STEP and parasolid files minimally

-software should include elementary ways to visualize, measure, and make modifications of STL files including repairing STL files both automatically and manually

-edit STL data by cutting bodies, inserting holes, surface extrusion, hollow-out, offset, logical operations (ex: join), triangular reduction, surface smoothing, labeling

-software should support position of components in build envelope, automatic nesting, part collision detection, height compensation, and beam diameter compensation

-software should be able to create support and anchor structures automatically to aid the build process

24). Build Processor (fixed license)

QTY = 1

-Software to calculate shifts and shading data according to the selected machine as well as material-specific parameters

- software generates the laser scan vectors.

25). Fixed license software to do the following (SG+ Module)

QTY = 1

-software tools needed to find the optimal orientation of part,

-software automatically selects and optimizes support, anchoring, and heat transfer fur builds.

26). Sensor data logging and visualization

QTY = 3

-3 year subscription.

-native software for plotting the sensor data to track sensor output of the machine and ensure print quality.

28). Applications Training

QTY = 1

-At least 2 days at customer site

-application training covers live machine demonstration, fundamental application training, advanced application training, consulting ramp-up, and offers some customized training

29). Installation + Operator Training

QTY = 1

-Machine installation, calibration, and machine operator training

-training includes material change training and maintenance training

30). Total service plan: one year.

QTY = 1

-service plan to cover parts, labor, travel, service visits (at least two per year min.)

-unlimited visits for corrective maintenance during year period

31). Material Change Kit for PSM

QTY = 1

Sieving channel for quick material change

32). 34" X 25"(WxD) 1.5HP Downdraft Table

QTY = 1

single sided downdraft table system

- Regain push/pull assist air

-34” wide x 25” deep fiberglass grated work surface directly connected to wet collector.

-Spark resistant 1.5 hp 120V TEFC motor, rated for 1,000 cfm.

HOW TO RESPOND TO THIS NOTICE

In responding to this notice, please DO NOT PROVIDE PROPRIETARY INFORMATION. Please include only the following information. Submit the response by email to the Primary Point of Contact at the bottom of this notice as soon as possible, and before the closing date and time of this notice.

• Provide the complete name of your company, address, name of contact for follow-up questions, their email, their phone number and, if your company has an active registration in https://sam.gov, your company’s CAGE code.

• Identify equipment that your company sells that is of the nature addressed in the BACKGROUND section of this notice. Include brand name, make, model, and/or other distinguishing information.

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  • Note that items 10, 23, and 25 above include references to specific brands that are known to meet the Government’s need/requirements. If your company is unable to offer these specific branded items or is otherwise aware of alternative branded items that are capable of meeting the identified minimum requirements, please provide sufficient technical documentation for the Government to evaluate to confirm that the alternative items indeed meet the minimum requirements.
  
  
  
  

• State if your company is the manufacturer of the identified equipment or is a retailer or wholesaler that normally sells the identified equipment. If the latter, indicate whether the manufacturer authorized in writing for your company to sell the identified equipment on behalf of the manufacturer.

• Describe performance capabilities and relevant or beneficial physical and functional features for any equipment you identified to satisfy the AFRL-identified minimum specifications described in this notice.

• Identify any aspects of the AFRL Sources Sought Notice, including instructions, and draft minimum specifications in the BACKGROUND section above that could be viewed as unduly restrictive or contain unnecessary barriers that adversely affect your ability to fully participate and indicate why. In such a scenario, please offer suggestions for how the market research notice and draft minimum specifications could be made more inclusive and competitive.

• For the NAICS code listed in this notice:

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  • Indicate whether your company is (a) a small business or (b) other than small business.
  
  
  
  

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  • If you believe the NAICS code listed in this notice is not the best NAICS code for the type of product addressed in this notice, identify an alternative NAICS code that you believe would be more appropriate for the planned procurement.
  
  
  
  

• Describe services that are available with the purchase of the aforementioned equipment from your company such as installation, training, and equipment maintenance.

• Describe standard terms and conditions of sale offered by your company for the aforementioned equipment such as: delivery time after your company accepts the order; FOB shipping terms: manufacturer warranty (including details regarding nature and duration); if available, description(s) of available extended warranty; equipment setup and test; operator and service instruction manual(s); cleanup after installation; and if applicable, other offered services.

• State whether the aforementioned equipment is manufactured in the United States and, if not, state the name of the country where the equipment is manufactured.

• Identify any customers in the public or private sectors in which you provided the aforementioned or similar equipment.

• Provide any other information that you believe would be valuable for AFRL to know as part of its market research for this requirement.

• State if you require AFRL to provide additional information to improve your understanding of the Government’s requirement.

QUESTIONS REGARDING THIS NOTICE

Questions regarding this notice may be submitted via email to the Primary Point of Contact listed in this notice.

IMPORTANT NOTES

The information received in response to this notice will be reviewed and considered so that AFRL may appropriately solicit for its requirements in the near future.

This notice should not be construed as a commitment by AFRL to issue a solicitation or ultimately award a contract.

Responses will not be considered as proposals or quotations.

No award will be made as a result of this notice.

AFRL is not responsible for any costs incurred by the respondents to this notice.

AFRL reserves the right to use information provided by respondents for any purpose deemed necessary and appropriate.

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