At this year's EuroMold in Frankfurt, Germany, the topic of e-Manufacturing will be dominated by industrial series production–whether it is in aerospace, the medical sector, or the toolmaking industry. The world market leader, EOS, will present several technological highlights (at stand F70 in hall 8.0) for increasing the quality and efficiency of e-Manufacturing with laser-sintering technology.

These new improvements include an entirely unique high-temperature system for processing high-performance polymers that are extremely well-suited for use in the aerospace industry and many other special applications. The EOS IQMS (Integrated Quality Management System) is being augmented with yet another important module through the introduction of an Online Laser Power Control (OLPC) that takes process control, parts quality and traceability in additive manufacturing to a whole new level. Another important EOS highlight at EuroMold 2008 is the Integrated Process Chain Management (IPCM) system for EOSINT M, which facilitates fast, user-friendly, and secure handling of metal powders and parts.

Focus on series production

"Our stated goal is to establish e-Manufacturing wherever there is a demand for highly complex and customized parts and products", says Dr. Hans Langer, founder and CEO of EOS in Krailling near Munich. "EOS's presence at this year's EuroMold therefore is devoted entirely to technical innovations that contribute to increasing the quality and efficiency of serial production with e-Manufacturing."

A world first: e-Manufacturing with high-performance polymers

Just in time for EuroMold, EOS presents a first in the industry highlight–the EOS P 800, which is the first high-temperature system for laser-sintering high-performance polymers. Because of their outstanding material properties, high-performance polymers are well suited for numerous applications such as aerospace or Formula 1. The EOS high-performance polyaryl ether ketone polymer, PEEK HP3, has a tensile strength of up to 95 MPa and a Young's modulus of up to 4400 MPa, values up to 100% above those attained by the PA 12 and PA 11 materials currently available. Depending on the field of application, the continuous operating temperature is between 180 °C (356 °F) and 260 °C (500 °F). This makes for excellent application-specific properties, such as flame retardancy, biocompatibility and sterilizability. Thanks to suitability for process temperatures of up to 385 °C (725 °F), the high-temperature system is the first equipment worldwide to make use of this remarkable material group for laser-sintering technology. The system is based on the sophisticated, tried-and-proven EOSINT P 730 and is built to withstand the demands of high-temperature processing with newly designed modules such as the processing chamber and exchangeable frame. EOS PEEK HP3 was the first high-performance polymer selected for use in the new system and readied for market by EOS.

Quality and efficiency innovations

EOS will also debut several innovations at EuroMold 2008 for enhancing the quality and efficiency of plastic laser-sintering. The new Online Laser Power Control (OLPC) unit, for example, ensures a more constant flow of energy to the part built through regular control and readjustment of laser energy. This enables EOS to enhance the part quality as well as improving quality control of the entire laser-sintering process. OLPC is available for the EOSINT P 730.

Another efficiency-increasing highlight in direct metal laser-sintering is the IPCM?M, which consists of various optional modules that can be used in a variety of ways to suit the customers' needs:

· A conveyor system facilitates fast and convenient emptying of metal powder from the EOSINT M systems.

· A sieve station for reused powder ensures constant powder and process quality and is capable of sieving even large amounts of powder. Laser-sintering operations are not interrupted during sieving, as was previously required.

· Exchangeable, clearly labelled powder containers in the IPCM-M furthermore enhance the traceability of the material used for manufacturing. This capability is important for fields of application such as the medical sector, where proof must often be provided of the origins and composition of the material used.

· Last but not least, a platform-handling module makes it easier to remove completed jobs from the system, even in conjunction with reference positioning of the building platforms.

All modules are designed for efficient and economical use, even with installations of multiple EOSINT M systems.

Just in time for EuroMold, EOS is also presenting various new materials that open the door to new e-Manufacturing fields of application. They include Inconel 718, which is frequently used to produce aircraft engines and other components subject to high stress levels.

At its stand at Euromold 2008, EOS will display the new high-temperature system as well as the familiar EOSINT M 270 and FORMIGA P 100 systems. The new solutions will be introduced at a press conference on Wednesday, 3.12.08, at 3:00 p.m. at the EOS stand.