Frequently Asked Questions
What are the advantages of Hybrid Manufacturing’s AMBIT System?
Some key advantages to our AMBIT system are:
We are the pioneers in this space. We are the ONLY company that can retrofit machine tools with additive without compromising the machine's capability. Our heads load with the existing tool changer on spindle center line, giving the maximum work area for laser deposition. The change-over between milling and cladding is fully automated offering significant time savings to the production cycle. Our system does not encroach on the CNC machine’s working envelope. We retrofit old and new CNC machines for individual customers as well as supply to machine tool builders for in-factory integration.
Can you compare your system to other machines in terms of capability assuming a similar CNC machine is retrofit with your system?
Most systems use the same fundamental technology to deposit by using a laser to melt metal powder in a process generically called “directed energy deposition” (according to ISO/ASTM). The main hardware difference is that the AMBIT™ system can tool change between multiple heads (each with unique optics) which provides a wider spectrum of deposition head choices enabling more flexibility for laser processing.
Honestly, at the moment I am undecided between your system and others on the market. Would you be so kind to explain me the merits/demerits of your system?
The DNA of our AMBIT products is significantly different than competing products because we enable:
AMBIT tool changeable heads make multiple types of processing practical in a single setup. For example, in mold repair, our customers can use a long reach head in hard to access areas and then benefit from higher deposition rates in easier access areas of the job. Using conventional systems this is impractical.
How dense is the deposited material?
For practical purposes, we say fully dense (>99%) subject to the quality of the feedstock powder you use. The condition of the feedstock is important since some feedstock powder can have voids inside of it, which often get transferred into the parts. Fortunately, it is typically a fraction of a percentage point, but for some people this can be an issue.
What metallurgical testing has been done on this process?
Over the course of our development, we have had a wide variety of metallurgical evaluations on parts produced by ourselves (usually evaluation was done by a 3rd party). Our systems in production for blade repair are routinely checked (however, this data is proprietary).
In general, the deposition is characterized by epitaxial growth and consistently achieves properties better than casting and is approximately equivalent to wrought properties. A link to a paper including some typical cross-sections is included here.
Metals We Do/Don’t Use:
What size feedstock particles do you use?
Typically we use feedstock powders with spherical (or potato) shaped particles from 20-45μm diameter or 45-90μm (or 120) diameter (the larger particle size is better with >500W of laser power). Narrower particle size distributions achieve higher quality depositions.
What powder suppliers can I use?
The AMBIT™ system is an open materials system which allows users to select from a wide variety of powder suppliers. Depending on the type of metal that you need, we are happy to suggest some suppliers that we use for high-quality metal powders. There isn't a single powder supplier that does all of the different types of powder that you will want. So plan to utilize more than one supplier for powder.
What is my investment?
There are a lot of factors taken into consideration to determine your initial investment. The cost of the installation of the AMBIT™ system onto a CNC machine varies based on the application (which determines the laser power needed. In addition, we will need to determine if there needs to be any custom engineering. For projects with a smaller machine/budget, we also have compact non-tool changeable heads available.
What is the delivery time?
Delivery time is approximately 16-18 weeks.
Some key advantages to our AMBIT system are:
- No changes to the machine structure required
- No compromise on machining performance
- Unlimited number of deposition and inspection heads
- Nearly 8 years of experience and intuition for applications in the area
- Foundational patents in the area
- We are not cannibalizing another product line to make hybrid machines
We are the pioneers in this space. We are the ONLY company that can retrofit machine tools with additive without compromising the machine's capability. Our heads load with the existing tool changer on spindle center line, giving the maximum work area for laser deposition. The change-over between milling and cladding is fully automated offering significant time savings to the production cycle. Our system does not encroach on the CNC machine’s working envelope. We retrofit old and new CNC machines for individual customers as well as supply to machine tool builders for in-factory integration.
Can you compare your system to other machines in terms of capability assuming a similar CNC machine is retrofit with your system?
Most systems use the same fundamental technology to deposit by using a laser to melt metal powder in a process generically called “directed energy deposition” (according to ISO/ASTM). The main hardware difference is that the AMBIT™ system can tool change between multiple heads (each with unique optics) which provides a wider spectrum of deposition head choices enabling more flexibility for laser processing.
Honestly, at the moment I am undecided between your system and others on the market. Would you be so kind to explain me the merits/demerits of your system?
The DNA of our AMBIT products is significantly different than competing products because we enable:
- Maximum flexibility through the option for multiple heads
- Optimal production - fully automatic changeover of different heads reduces cycle time and makes it practical to use heads optimized for specific features in the same setup
- Maximized working volume through spindle center-line deposition, we preserve virtually the entire working volume of the machine
- Future-proof expansion - you can add additional heads as needed from an expanding range of deposition and inspection heads
AMBIT tool changeable heads make multiple types of processing practical in a single setup. For example, in mold repair, our customers can use a long reach head in hard to access areas and then benefit from higher deposition rates in easier access areas of the job. Using conventional systems this is impractical.
How dense is the deposited material?
For practical purposes, we say fully dense (>99%) subject to the quality of the feedstock powder you use. The condition of the feedstock is important since some feedstock powder can have voids inside of it, which often get transferred into the parts. Fortunately, it is typically a fraction of a percentage point, but for some people this can be an issue.
What metallurgical testing has been done on this process?
Over the course of our development, we have had a wide variety of metallurgical evaluations on parts produced by ourselves (usually evaluation was done by a 3rd party). Our systems in production for blade repair are routinely checked (however, this data is proprietary).
In general, the deposition is characterized by epitaxial growth and consistently achieves properties better than casting and is approximately equivalent to wrought properties. A link to a paper including some typical cross-sections is included here.
Metals We Do/Don’t Use:
- We work with non-reactive metal powders including steel, stainless steel, tool steels (steels that are extra hard), nickel-based superalloys such as Inconel 625 and 718, Hastelloy, Waspaloy, and cobalt alloys such as Stellite
- Generally if it can be welded it can be laser clad.
- We do not prepare the system commercially for reactive metals such as titanium, aluminum, and magnesium, etc. at this time
What size feedstock particles do you use?
Typically we use feedstock powders with spherical (or potato) shaped particles from 20-45μm diameter or 45-90μm (or 120) diameter (the larger particle size is better with >500W of laser power). Narrower particle size distributions achieve higher quality depositions.
What powder suppliers can I use?
The AMBIT™ system is an open materials system which allows users to select from a wide variety of powder suppliers. Depending on the type of metal that you need, we are happy to suggest some suppliers that we use for high-quality metal powders. There isn't a single powder supplier that does all of the different types of powder that you will want. So plan to utilize more than one supplier for powder.
What is my investment?
There are a lot of factors taken into consideration to determine your initial investment. The cost of the installation of the AMBIT™ system onto a CNC machine varies based on the application (which determines the laser power needed. In addition, we will need to determine if there needs to be any custom engineering. For projects with a smaller machine/budget, we also have compact non-tool changeable heads available.
What is the delivery time?
Delivery time is approximately 16-18 weeks.
