METAL 3D PRINTING COMBINED

WITH hyperMILL – THE PERFECT SOLUTION

hyperMILL CAD/CAM system ensures a perfect handshake between

metal 3D printing and reworks machining.

hyperMILL & 3D printanje
Michael Meyer using hyperMILL

Metal 3D printing has become an established industrial manufacturing process in recent years. Powder bed-based metal laser melting processes are particularly popular as they create a highly homogeneous, microstructure with minimal voids and a density exceeding 99.8 percent.

Interestingly, the parts produced with selective laser melting technology are, on average 20 to 30 percent more mechanically resilient than die-cast aluminum parts.

COMBINING 3D PRINTING & MACHINING – THE FUTURE OF THE OFFER?

Parare GmbH is a manufacturing service provider specializing in the industrial metal and plastic 3D printing. Already in the past, the company recognized the potential of this technology. 3D printing is a direct manufacturing process based on CAD data, with no tools, molds, or CAM programming required to generate the part. 

The more complex a component is, or the more conventional consecutive manufacturing steps are required, the more sense it makes to resort to 3D printing because, with additive processes, complexity has little impact on cost. Therefore, their offer is primarily suitable for prototyping and small-batch projects where building time-consuming and costly die casting tools would not be viable. 3D printing also addresses scenarios such as the low-volume construction of replacement parts.

Parare - 3D print & CNC
Nihajna roka izdelana s hyperMILL

This weight- and force-flow-optimized swing arm was created using a powder bed-based metal laser melting process. It has numerous faces that require rework machining.

“We recognized early on that the interface between 3D printing and rework machining is of great importance. This also applies to the CAD/CAM system used. hyperMILL CAD/CAM from OPEN MIND is the perfect solution for us.”

 – Sven Skerbis, Parare Managing Director

COMPLETE SERVICE PROVIDED BY hyperMILL CAD/CAM

Parare gmbh using hyperMILL

Matthias Bath (left) and Sven Skerbis founded Parare GmbH in 2017. The manufacturing service provider specializes in the industrial metal and plastic 3D printing.

Parare transfers its knowledge to customers and shows them where the use of 3D printing makes sense. They assist with the design and topology optimization stage and then produce the components. They also perform rework machining, so their customers receive the best final products possible.

The powder materials used in selective laser melting (SLM) are traditional alloys comprising stainless steel, tool steel, titanium, aluminum, and nickel-based materials. As the laser melts one layer at a time, the components require additional structures to support areas that cannot support themselves in the powder, such as walls with slopes exceeding 45 degrees. These supports have to be removed afterward. In addition, further machining is required in some cases for functional and sealing surfaces, fits, and threads to ensure the required level of precision and surface quality.

hyperMILL CAM programska oprema

IMPORTANT REWORK MACHINING INTERFACE

Previously, Parare outsourced this final step to partners. Experiences have taught them that the interface to rework machining is very critical. If the person programming or machining the part did not create the raw data for 3D printing themselves, this will often result in long machining times and, in the worst case, errors. The costs of generating rejects at this stage are very high.

For this reason, in early 2019 the Parare management started to pursue the goal of handling rework machining themselves. They set out to find a suitable employee, a powerful 5-axis machining center, and suitable CAD/CAM software.

hyperMILL & additive manufactured part

TIME TO (FINALLY) REACH FOR hyperMILL CAD/CAM SOFTWARE?

5-osno programiranje v hyperMILL

Rework machining of additively generated components is usually handled with 5-axis technology. hyperMILL offers machining cycles for this purpose.

The company opted for a Hermle C30 U and was introduced to the hyperMILL CAD/CAM system from OPEN MIND Technologies AG.

Michael Meyer, who is now in charge of programming and machining, is highly satisfied with hyperMILL and the integrated hyperCAD-S, which is the “CAD for CAM” system. He has been working with this software for over ten years, and he doesn’t know of any other system that can hold a candle to hyperMILL regarding 5-axis machining. In addition, hyperCAD-S allows him to easily add geometric solids and faces to the supplied CAD data or repair faulty faces.

CREATING 3D PRINTABLE COMPONENTS WITH hyperCAD-S

Most of the time, Parare receives CAD part manufacturing data from the customer. Since this is not suitable for 3D printing, they are first transferred to hyperMILL and then further processed using hyperCAD-S. Michael Meyer checks the faces, touches them up, and adds support structures and clamping straps where necessary. He calculates the required allowance for the places that need to be reworked to ensure optimal milling. He then transfers the file back to the CAD system, which outputs it as an STL file for the SLM process.

Michael Meyer programira v hyperMILL

Production Manager Michael Meyer edits and adds to the
component data in hyperCAD-S even before 3D printing.

hyperMILL ENSURES THE RIGHT 5-AXIS STRATEGIES FOR ANY APPLICATION

Simulacijska orodja v hyperMILL

Simulation tools in hyperMILL ensure
safe machining on the 5-axis machining center.

Michael Meyer’s enthusiasm does not stop with the CAD side of hyperMILL, but also extends to the CAM programming itself. The structures created in 3D printing are often very complex and can only be processed with 5-axis technology. This is precisely one of the strong points of hyperMILL because it provides several tilt strategies. This allows him to select a suitable solution for every geometry, material, and machine kinematics.

SHORT PROGRAMMING TIMES THANKS TO FEATURE AND MACRO TECHNOLOGY IN THE hyperMILL

What Michael Meyer particularly likes about the hyperMILL is macro programming. With its feature and macro technologies, and associated processes, hyperMILL provides a solid basis for automated programming. This saves him a lot of time even at the programming stage. Incidentally, this applies not only to rework machining but also to other complex milled parts.

For Michael Meyer, a well-maintained tool database is a key to efficient programming and reliable machining. Also at this stage, hyperMILL provides a very viable solution.

Hermle C30 U machining with hyperMILL

Flexible, precise, and rigid – Hermle C30 U together with hyperMILL ideally suits the requirements of Parare.

Parare’s machining center, which is used both for finishing and roughing processes, must also be reliable. To program the pre-machining, Michael uses the roughing module of the hyperMILL MAXX Machining performance package, which offers solutions for high-performance cutting (HPC) with spiral and trochoidal tool movements. The package combines optimal milling paths, maximum material removal, and minimized machining times.