Focus on structural optimization and lightweight construction

Changes in component design go hand in hand with new manufacturing technologies such as additive manufacturing. Metallic 3D printing is the future, but it is by no means trivial – especially for large components measuring more than 600 x 600 mm. For prototyping or small series with batch sizes from one to five, the technology is definitely a perfect fit!

Bionic structures are extremely valuable for additive manufacturing, as they allow considerable savings to be made in operating costs, for example by eliminating assembly work. In addition, bionic structures offer added value because they are accompanied by functional optimizations. The design is based on nature´s “blueprints” and adapts them to technical applications. At the same time, a bionic structure leads to lower weight, optimized material use and load distribution within the component – in other words, to improved performance overall.

Kurtz Ersa develops components in collaboration with the customer using the additive powder bed process LPBF (short for: Laser Powder Bed Fusion), optimizes them and demonstrates the advantages of a bionic design. Lightweight solutions and the production of small series with complex shapes are central goals. Complex geometries are often not feasible with conventional technologies – or only at significantly higher costs. Metallic 3D printing reduces the number of process steps required for shaping or joining, for example.

Motorcycle swing arm (625 x 370 x 280 mm) manufactured in 1/3 of the possible installation space of the Kurtz Ersa Flying Ray © RWTH Aachen University - Digital Additive Production DAP

The planetary gear unit (here diameter 450 mm, also 900 mm possible) proves that even components of the greatest shape complexity can be produced without any problems

THINK BIG: High Quality in 3D Printing

With an installation space of 1,500 x 1,000 x 500 mm, the Kurtz Ersa Flying Ray is optimally equipped for the metallic 3D printing of large components. In the basic version, eight power adaptive lasers are used simultaneously on eight swivel arms. The multi-head printer was developed in a modular design to enable adaptation according to individual customer ideas and component requirements. Modular design options include: Number of lasers, number and length of axes, center distance and overlap area of the swivel arms.

Let´s fly!