Farsoon Technologies, Changsha, Hunan, China, has introduced a new large-frame Laser Beam Powder Bed Fusion (PBF-LB) machine, the FS621M. In developing the industrial-scale metal Additive Manufacturing machine, the company aimed to address some of the challenges faced by industry, including machine productivity, part size constraints, powder management, process control and factory layout.

Farsoon is a global manufacturer and supplier of industrial level polymer and metal Additive Manufacturing systems. It established Farsoon Technologies-Americas in Austin, Texas, USA, in 2017, and in 2018, Farsoon Europe GmbH was established in Stuttgart, Germany, to expand direct operations in Europe.

The company developed the FS621M in collaboration with industry partner Falcontech co., LTD., Wuxi City, Jiangsu, China, a leading manufacturing service provider in the aerospace industry, with a focus on extending the machine’s build cylinder volume and increasing maximum productivity per laser. Being an important part of Falcontech’s new Super AM Factory, the FS621M system is expected to give Falcontech an advantage in metal additively manufacturing components for large aerospace applications.

The new machine features a build platform size of 620 × 620 mm and vertical axis of 1.1 m. This build envelope offers new possibilities for large-scale metal production that, according to Farsoon, were not previously possible in industries such as aerospace, oil and gas, and many others.

The FS621M can be equipped with a single 1000 W laser or four 500 W lasers, allowing for higher rates of production. Like all Farsoon machines, it operates on an open platform which offers the user a high degree of control to tailor build parameters for cost-competitive metal AM. An advanced dynamic three-axis scanning system, powerful build process controls and real-time recoating monitoring are also said to help ensure build quality.

The FS621M large-frame metal AM machine offers a build platform of 620 x 620 mm and a vertical axis of 1.1 m (Courtesy Farsoon Technologies)

The machine also incorporates an integrated filter module, a secondary circulating system and a dual-station filter design, allowing for the exchanging of filters without disturbing the build process. The FS621M’s powder handling processes share a common powder container design, which is used during loading, unloading and sieving procedures. These containers offer fully-sealed powder handling, easy transportation between stations and safe storage of powder.

The total installed base of FS621M machines currently numbers seven among aerospace and large-scale manufacturing customers which focus on large-volume AM, batch production, and process development for the AM of industrial powder materials including titanium and aluminium alloys, nickel-base superalloys and stainless steels. Falcontech reports that it has succeeded in supporting the development and series production of spacecraft components by AM in a number of aerospace projects.

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