--- title: "Incodema3D scales production with EOS metal AM" url: https://www.voxelmatters.com/incodema3d-scales-production-with-eos-metal-am/ date: 2024-10-12 modified: 2024-10-23 lang: en author: "Tess Boissonneault" description: "Known best for its many waterfalls and beautiful lakefront, the city of Ithaca in the state of New York is also home to a leading metal AM contract manufacturer, Incodema3D...." categories: - "3D Printing Service Providers" - "AM Factories" - "Executive Interviews" - "Metal Additive Manufacturing" tags: - "Featured" image: https://www.voxelmatters.com/wp-content/uploads/2024/10/EOS_App_Aerospace_TurbineBlade_EOSNickelAlloyIN393_EOSM290_16-640x427.jpeg word_count: 964 --- # Incodema3D scales production with EOS metal AM Known best for its many waterfalls and beautiful lakefront, the city of Ithaca in the state of New York is also home to a [leading metal AM contract manufacturer, Incodema3D](https://www.voxelmatters.directory/company/incodema-group/). The company, which was founded in 2016, already has over 20,000 projects under its belt, largely in the fields of aerospace, defense, and power generation. The metal AM service’s prominent position in the broader metal AM industry is owed in large part to its strong ties to additive manufacturing OEMs, including [powder specialists Elementum 3D](https://www.voxelmatters.directory/company/elementum3d/), [6K Additive](https://www.voxelmatters.directory/company/amastan-technologies/), [depowdering solutions provider Solukon](https://www.voxelmatters.directory/company/solukon-maschinenbau-gmbh/) and, most notably, [AM hardware company EOS](https://www.voxelmatters.directory/company/eos/), whose metal 3D printers form the backbone of Incodema3D’s production offering. ## 35 3D printers strong Today, [Incodema3D operates a fleet](https://www.voxelmatters.com/incodema3d-acquires-eos-m-290s-eos-m-400-metal-systems/) of 35 metal additive manufacturing systems, including nine EOS M280 3D printers, three EOS M 290 machines, four EOS M 400, four EOS M 400-4, and 15 EOS M 300-4 systems. The commitment to EOS hardware is owed to a few factors. For one, as Sean Whittaker, founder and CEO of Incodema3D, explains: “When our clients began adopting the EOS platform to develop designs for their production programs, we focused on aligning our business to support their print specifications.” Additionally, EOS is known for manufacturing reliable metal AM solutions that can offer benefits in terms of production performance, efficiency, and economics. Notably, EOS’ powder bed fusion technology was recently recognized as the “most profitable additive manufacturing process” in the 2024 Wohler’s Report. ![](https://www.voxelmatters.com/wp-content/uploads/2024/10/Incodema3D_Shop_Floor_Image1-scaled.jpeg) “EOS system reliability and field service have enabled high, sustained machine utilization rates which drives down part pricing and opens the doors for large, long-term programs,” added Matt Lewis, Vice President of Programs at Incodema3D. [The EOS M 300-4 in particular](https://www.voxelmatters.com/rennscot-mfg-enters-metal-am-space-with-purchase-of-eos-m-300-4/), developed by EOS for high productivity and an automated workflow, has proven to be an ideal match for Incodema’s production requirements. “The M 300-4 offers multi-laser speed with the added flexibility on laser assignment and stitch line strategy,” explained Kevin Engel, Director of Additive Operations at Incodema3D. “All of this comes at an aggressive capital equipment cost that is the best offering EOS has per laser hour, allowing Incodema3D to offer the latest technology at a more affordable price to our customers.” The system, which has a build volume of 300 x 300 x 400 mm, is equipped with four 400w fiber lasers, which can achieve a scan speed of 7 m/s. The system’s productivity is also in part due to a dual recoater system that minimizes the time between each laser exposure, for productivity rates of up to 10 times higher than competing systems. ![](https://www.voxelmatters.com/wp-content/uploads/2024/10/EOS_BuildingProcess_Metal_02-scaled.jpeg) ## Scaling series production Notably, Incodema3D’s metal AM fleet has grown substantially in the past year, as the company [first added four](https://www.voxelmatters.com/incodema3d-acquires-four-eos-m-300-4-systems/), then [another six EOS M 300-4 systems](https://www.voxelmatters.com/incodema3d-acquires-6-more-eos-m-300-4-metal-3d-printers/), to address increasing production demand. The contract manufacturer also has more expansion plans at its current facility and is planning to scale its capabilities at other locations in 2026 and 2027. “Uptime, ease of use, and the ability to scale production,” said Whittaker of the key reasons why EOS’ technologies are Incodema3D’s focus. “We chose the EOS M 300-4 because our current fleet of EOS printers are operating near 90% production utilization, so we need the fastest systems on the market to enable the growing production needs of our customers. The EOS M 300-4 is a production workhorse, and our technicians rave about how user-friendly and reliable of a system it is.” Much of the recent growth experienced by Incodema3D is due to maturing application development programs and increased production for clients, especially in the defense sector. According to the company, its work has transitioned significantly from R&D to full-on production in the past couple of years as development projects that have been in the pipeline become ready for series production. “Most of our growth has occurred as long-developed programs moved from qualification to low-rate and then full-rate production,” said Lewis. “These volumes have varied from tens of pieces to over 100,000 pieces.” ![](https://www.voxelmatters.com/wp-content/uploads/2024/10/Incodema3D_Sean_Whittaker_Founder_Image2-scaled.jpeg)Sean Whittaker, CEO of Incodema3D. In terms of applications, Incodema3D has the expertise and capacity to fulfill a range of different metal AM production applications at its facility of over 60,000 square feet, however, its specialty is in thermal management systems for the aerospace, defense, and power generation industries. To meet the varying needs of its clients, the company has developed a deep knowledge of end-to-end metal AM, including post-processing and quality assurance, as well as a broad range of high-performance metal powders. “Incodema3D has experience running over [30 different materials in EOS machines](https://www.voxelmatters.com/eos-will-assemble-the-eos-m-290-metal-3d-printers-in-texas/),” Engel elaborated. “With the parameter editor, we have the option to run default EOS parameters that are already at a high TRL level or develop our own parameters for unique alloys. Our core production business is around a small handful of those alloys, but we still maintain the flexibility to run additional materials.” Among the materials currently compatible on the AM service’s workhorse system, the EOS M 300-4, are EOS StainlessSteel 316L, EOS Aluminum AlSi10Mg, EOS Titanium Ti64, EOS MaragingSteel MS1, EOS NickelAlloy IN625, EOS NickelAlloy IN718 and EOS StainlessSteel 17-4PH. For obvious reasons (NDAs), Incodema3D can’t disclose any specific series production jobs it is working on, but it has long-standing relationships with its clients and has played a key role in advancing metal AM applications to scalable series production. ![](https://www.voxelmatters.com/wp-content/uploads/2024/10/Incodema3D_Building_Image3-scaled.jpeg) “Simply put we are a contract manufacturer,” concluded James Hockey, Director of Business Development at Incodema3D. “We provide our client with the capacity to produce their components. Although we can provide development for a potential production program, we typically receive client-developed production components ready for manufacturing. We don’t just print parts, we manufacture parts …to print!” *This article was originally published in VoxelMatters’ VM Focus AM Services eBook. Read or download the full eBook for free at [this link](https://www.voxelmatters.com/voxelmatters-am-services-focus-2024-ebook/).*