Further manufacturing walk through
Given Electricity is 2kwh per hour .5Euro/hr
previous examples ignoring ion beam correction gave A 2480 min 1.7 days B 248 min 4 hrs
with seperate second SEM electron Gun with XY mechanical movement
at max 0.3m per second then part A 3300 min 2.3 days B 330 min 5.5 hrs
So 40 percent longer manufacturing time as well as 2 extra motors ( one vacuum tolerant / expensive ) and extra position sensors and extra computer processing putting the patches together as one image. But advantage of normal sized PIN diode sensors for SEM in backscatter mode as sensors only 0.1m from sample like a traditional SEM rather than 1m distance from sample a new situation.
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
7.5 minute per Every 10th layer Z axis correction ; SEM ( part assumed to occupy 1/9 of whole print area; 1/9* 300*300=10 000mm2 measurement at every 10µ, SEM picture 500x500 pixel so 5mmx5mm, So for 10,000mm2 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. plus time of mechanical movement of electron gun between .012m square patches at .03m per second is 25y strips each .3m strip takes 10 seconds to travel, so in all takes 250 seconds( Risk of underestimate factor x100 ) 5.5min
Remove metal by Vaporization 1ms per 70µ diameter spot area 4000x10-6 mm2 ( 850µs duration & 150µs beam movement) 1/10 of part high(Risk of underestimate factor x2) ( 1/10*10 000mm2/ 4000x10-6 mm2= 1x105 spots 1x105 spots*1ms= 100Sec 2min Time so far 200* Z correction layers 7.5 Min each 1500 + 1800 printed layer 1min each = 3300 min ( 2.3 days)
Time total so far 200* Z correction layers 7.5 Min each 1800Min + 1800 printed layer 1min each 1800 = 3300 Min
Cost 690 Euro materials 600Euro Electricity 90
Part B Aluminum size 300x300x20mm 1.5Kg
Aluminum 15Euro 10µ powder, melt print 100µ Z layer thickness
Time 20* Z correction layers 7.5 Min each + 180 printed layer 1min each = 330 Min 5.5 hours No ion beam abraison Cost 27 Euro materials 22 Euro Electricity 5 Euro
