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Additive Manufacturing

Surface Finishing for Metal Additive Manufacturing Applications

As-Built Surface

As-Built Surface

Extreme ISF® Surface

The Metal Additive Manufacturing (Metal AM) Industry is revolutionizing manufacturing processes and part design.  However, the industry faces challenges as it seeks to move into new and more challenging applications.

Poor surface finish and limited fatigue life are two of the largest challenges present in as-printed Metal AM components.  REM’s Extreme ISF® Process technologies address both of these challenges.

REM’s Extreme ISF Process (a suite of isotropic superfinishing/polishing processes) has been shown to significantly improve Metal AM component fatigue life (matching machined component performance in some cases) and is capable of finishing the extremely challenging geometries that generative design and design for additive manufacturing (DfAM) are known to produce.

Component Benefits for Metal Additive Manufacturing Applications:

  • Increased Dynamic Fatigue Performance/Resistance to Bending Fatigue
  • Increased Tensile Strength
  • Improved Laminar Flow Properties/Reduced Turbulence
  • Eliminated FOD Risk
  • Removal of Surface Roughness & Surface Waviness
  • Elimination or Remediation of Surface Defects
  • Improved Component Cleanliness
  • Improved Aesthetic Appearance

Production Benefits for Metal Additive Manufacturing Applications:

  • Removal of All Loose & Partially Melted/Sintered Particles
  • Removal or Reduction of Support Structures
  • Improved Component Inspection Capability (FPI, MPI, etc.)

Common Metal Additive Manufacturing Alloys REM can Assist with:

  • Titanium Alloys (ex. Ti 6AI-4V)
  • Nickel-based Superalloys (ex. IN-625, IN-718, HX, JBK-75, NASA HR1)
  • Stainless Steels (ex. 17-4 PH, 15-5 PH, 316/316L)
  • Carbon Steels (ex. Ferrium® C64)
  • Maraging Steels
  • Copper Alloys (ex. GrCOP-42, GrCOP-84)
  • Aluminum Alloys (ex. AlSi10Mg, Al6061, A205, A20X)
  • Low CTE Alloys (ex. Invar 36®)
  • Bulk Metallic Glass Alloys

Metal Additive Manufacturing Categories the Extreme ISF Process can Improve:

  • Electron Beam Melting (EBM/E-PBF)
  • Laser Beam Melting (L-PBF, DMLS, DMLM, SLM, etc.)
  • Powder Directed Energy Deposition (Powder DED, Blown Powder, LENS, DMD)
  • Wire Directed Energy Deposition (Wire DED, EBAM®)
  • Metal Fused Deposition Modeling/Metal Fused Filament Fabrication (Metal FDM, Metal FFF, BDM™)
  • Binder Jetting

Interested in learning more, ready to start a project, or have an application that you don’t see listed here?  Contact us today to see how we can help solve your surface finishing/polishing needs.

As Built Additive Surface

 As-Built Surface

Extreme ISF Additive Surface

Extreme ISF® Surface

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