The Matsuura LUMEX Avance-25 utilizes metal laser sintering and high-speed, high-precision milling to form metal powder into shapes and make deep ribs in a single process. According to the company, the LUMEX Avance-25 provides molds with dimensional accuracy and surface smoothness at almost the same level as machining centers.
The technology works as follows: metal powder as sintering material is first laminated to a thickness of 0.05 mm on the base plate located on the table. Then, the machine irradiates the laser beam to sinter the metal powder into the product shape to be bonded to the processing table. After the metal powder is sintered, the LUMEX Avance-25 squeezes and supplies metal powder with a thickness of 0.05 mm to form the next layer and sinter all the laminated layers. After several layers of sintering, an end mill performs the high-speed milling of the contour of the mold to a finish. The machine does not cut the product to a finish after all the sintering of the product is finished. Instead, the LUMEX Avance-25 repeats the sintering and milling of the product to construct the bottom layer to the top layer, no matter how complicated the internal shape might be. So while sintering-only technology leaves a coarse surface finish, laser sintering/milling hybrid technology produces finished components in a single set-up, with a surface finish comparable to that of a traditionally machined component.
"The LUMEX Avance-25 eliminates conventional processes, such as mold die splitting, electrical discharge processing and electrode designing for deep rib formation, all of which would otherwise require advanced skill sets to accomplish," said a company spokesperson. "The simplified process reduces material cost and reduces the reliance on skilled machinists and tool makers. The machine also eliminates the need for fabrication of additional internal cooling water pipes and assembly and adjustment work, thus reducing the required time of mold die designing and processing. The LUMEX Avance-25 fabricates complicated mold dies at a stretch, again, without splitting them. Because of this capability, this hybrid machine creates a fundamental change in common knowledge for mold die making. All of these features assist in supporting the quick launch of new products and other situations where high-mix, low-volume production is commonplace.
"Because the LUMEX Avance-25 can machine a number of mold dies without splitting them, it reduces the required time of designing and computer-aided machining (CAM) time. The LUMEX Avance-25 saves the required designing time and CAM processing time of mold dies by approximately 23% and 90%, respectively, even if the mold dies have a large number of deep ribs, and reduces the required machining time by at least 50%. The LUMEX Avance-25 saves a total of 61.5% of metal manufacturing time compared with the conventional work method.
"The LUMEX can freely make sintering density changes for the placement of porous structures and air permeability control without restrictions, thus performing gas venting more effectively than any other machine - improving the quality of molds. Users can make porous structures for gas venting in any place, thus preventing molding problems such as gas burning, weld line formation, and shrinkage and contributing to quality improvements."
For more information contact:
Mitsubishi EDM
c/o MC Machinery Systems, Inc.
1500 Michael Drive
Wood Dale, IL 60191
630-616-5920
mitsedm@mcmachinery.com
www.mitsubishi-world.com