MX3D to launch new MX Metal AM System at FormNext Forum Austin

MX3D, an AMsterdam-based company specializing in Robotic Wire Arc Additive Manufacturing (i.e. WAAM or Wire-Arc DED), is launching the new MX Metal AM System, its second turnkey robotic metal AM system, after the M1, for 3D printing larger certified metal parts. The system will make its debut at Formnext Forum Austin on August 28th.

The MX Metal AM System will MX3D’s customers to cost-effectively replace cast and forged parts with significantly improved lead time and quality. The new machine operates on multiple adjustable build plates, including a heavy-duty 2-axis positioner, and manufactures parts that weigh 5 tons or more. The system has an equally impressive build volume of 6 x 1.5 x 3.5 meters.

“Several of our customers see opportunities for applying WAAM on much bigger parts. Especially in the energy and maritime industry where they will replace large casted or forged parts with 3D printed parts to accelerate the lead time, bring down cost and reshore production of critical parts”, said Gijs van der Velden, CEO of MX3D. “Since the launch of MetalXL and the M1, we have received many customer requests about whether we could supply them with a system capable of printing radically larger parts. The MX Metal AM System is the answer to this call. Now customers can also print very large and extra heavy certified metal components in-house, accelerating 24/7 automation and operational excellence”.

The new system includes an 8-axis heavy-duty industrial robotic setup, high productivity power source and the MX3D 24/7 automation package. All elements are fully integrated with the latest version of MX3D’s proprietary end-to-end workflow software and control system MetalXL, the fully upgraded MetalXL 4.0 package.

This latest version of the MX3D’s MetalXL workflow software and control system, supports various new productivity tools, dynamic sensors and active closed-loop processes to push autonomous 24/7 printing of qualified industrial metal parts to the next level.

The MX Metal AM System was developed based on requests by various industrial customers who operate in the energy, manufacturing and maritime industries to print larger-scale metal parts.

Large-scale industrial metal parts are commonly casted and forged in remote locations or fabricated by scarce welding specialists. With current supply chain challenges, this results in long lead time, driving downtime and associated operating costs to extremes.

Robotic WAAM or Wire-DED is well known for its capabilities to print large-scale metal parts at high speed and with strong material and mechanical properties for various metal alloys. Due to its high level of robotic flexibility, automated productivity tools and integrated sensors system, the extended and heavy-duty robotic system can run autonomous 3D metal printing at an even faster speed, higher quality and lower operating costs at larger volumes and variants in-house.

“The MX Metal AM System is an impressive production system and by far the largest AM system MX3D released to the market. It certainly is the heavyweight champion of Metal 3D Printing. We specifically configured it for our customers in the heavy industry markets, and we engineered it to ensure speed, quality, and cost-effectiveness for the production of large-scale metal parts. The new MetalXL 4.0 is a huge software update and pushes advanced toolpathing to another level. Pair this with the heavy robotic capabilities of the MX Metal AM System, and you are able to produce complex parts of multiple tons. Given the all-new parameter dashboard and the new sensor packages, it has never been easier to unlock the high productivity level for continuous 24/7 printing. We are very proud that MX3D once again raises the standards of large-scale metal printing, by consistently delivering tailored software and hardware solutions that redefine the industry.” said Thomas Van Glabeke, CPO of MX3D

Next to the company’s flagship M1 Metal AM System, providing an optimized standard turnkey solution for WAAM, the new MX Metal AM System offers a fully customizable robotic system to print large-scale metal parts. Utilizing renowned brands like ABB and KUKA robotics and Fronius’ advanced welding equipment, customers have a wide range of hardware options to configure the perfect system for printing large, heavy and custom metal components.

The integrated productivity tools such as an automatic tip changer, active cooling and advanced sensors in the MetalXL Control System drive high print quality at high speed and control. The MX Metal AM System can be optimized by various heavy-duty-cycle power sources to achieve higher print speeds at >10kg/hr deposition rate, and configured for multi-material printing of various metal alloys. All are fully integrated and automated by the proprietary MX3D workflow platform and control system for flexible, controlled and advanced robotic 3D metal printing, used by companies such as BMW Group, Shimoda Iron Works, Dalhousie University, Whittaker Engineering and many more.

The MX Metal AM System can be further expanded by several additional sensors including advanced thermal cameras, 3D scanner, weld pool camera and acoustic emission sensors. With the M1 and MX Metal AM Systems, MX3D now has a full range of robotic system configurations to 3D print large-scale certified metal parts in-house at high speed, high quality and low costs, tailored to any large-scale and custom industrial application.