Further manufacturing walk through
Second electron gun for SEM postiioned close to the sample with mechanical XY positioning
Given Electricity is 2kwh per hour .5Euro/hr
Part A Stainless size 300x300x200mm 15Kg
10µ Stainless powder (40Euro/kg) melt print 100µ Z layer thickness
1 minute per Z 100µ each layer heated melting-point – 20 0C then printed by beam
3.4 minute per Every 10th layer Z axis correction ; SEM ( part assumed to occupy 1/9 of whole print area; 1/9* 300*300=10 000<math>mm^2</math> measurement at every 10µ, SEM picture 500x500 pixel so 5mmx5mm, So for 10,000<math>mm^2</math> need 400 SEM pictures 10,000/25= 400 4x pictures from 4 picups gives effect of different angles? for 3D picture reconstruction so real distances, 400 5mmx5mm pictures, 250ms a picture 400x.25 Sec = 100Sec or 1.66 min ( Risk of underestimate factor x100 )
Remove metal by Vaporization 1ms per 70µ diameter spot area 4000x10-6 <math>mm^2</math> ( 850µs duration & 150µs beam movement) 1/10 of part high(Risk of underestimate factor x2) ( 1/10*10 000<math>mm^2</math>/ 4000x10-6 <math>mm^2</math>= 1x105 spots 1x105 spots*1ms= 100Sec 1.66 min Time so far 200* Z correction layers 3.4 Min each + 1800 printed layer 1min each = 2480 min ( 1.7 days)
To add a 40mmx4mm = 160<math>mm^2</math> bearing surface by removing up to 40µ to achieve 0.1µ specification Ion beam abrasion 20min per 1<math>mm^2</math> 160*20min =3200min
Time total so far 200* Z correction layers 3.4 Min each 1800Min + 1800 printed layer 1min each 1800 = 2480 Min + ion beam bearing surface 3200= 5680( 4 days)
Cost 665 Euro materials 600Euro Electricity 65
Part B Aluminum size 300x300x20mm 1.5Kg
Aluminum 15Euro 10µ powder, melt print 100µ Z layer thickness
Time 20* Z correction layers 3.4 Min each + 180 printed layer 1min each = 248 Min 4 hours No ion beam abraison Cost 25 Euro materials 22 Euro Electricity 3 Euro
