InssTek Is Revolutionizing Alloy Research Globally With the MX-Lab DED 3D Printer

Directed energy deposition (DED) is one of the more versatile metal additive manufacturing technologies. Used for everything from large metal parts to repairs, the process is gaining popularity in different sectors. One area where we are particularly seeing a growing interest in DED printing is in material research. This can be seen with the MX-Lab 3D printer which has been designed for this very purpose.

The South Korean industrial 3D printing solution provider, InssTek, has seen significant global success with its metal 3D printing machine, MX-Lab, attracting top universities and research institutions worldwide. The recent sales to the Institut Jean Lamour (IJL) the University of Lorraine have further accelerated MX-Lab’s successful global expansion. Additionally, installations are currently underway at other universities and research institutions especially for those working in metallurgy and alloying, or the mixing of metals to make alloys.

But how exactly can DED be used in this for material research? How can you adopt the technology if you have little experience with metal AM? Why would you choose this 3D printer? We took a closer look at the MX-Lab 3D printer to better answer these questions. Not to mention, attendees at Formnext 2024 can also see the machine at InssTek’s Booth, D98, in Hall 12.0.

A Closer Look at the MX-Lab 3D Printer

Before we can look at the applications, it is necessary to understand the MX-Lab 3D printer itself. As mentioned, this 3D printer uses DED 3D printing with InssTek’s very own Direct Metal Tooling (DMT®) technology. This process from the Korean manufacturer is notable for being one of the most precise forms of DED technology with powder being melted directly by a laser and with two vision cameras that can analyze and control the height of the melt pool in real-time. The MX-Lab has been designed as an entry-level solution for the DED process, making it even more accessible to research applications.

Research labs in many different countries have published papers where the MX-Lab 3D printer has been used

The build volume of the MX-Lab measures 150 x 150 x 150 mm and it uses a Ytterbium Fiber Laser. The compact size allows researchers to design and conduct experiments with flexibility and ease. The max power of the laser is 500 watts, with an average wattage of about 300.

Furthermore, the solution has been designed for easy installation and has been specially optimized for material research. Its user-friendly interface and advanced capabilities enable scientists and engineers to explore a wide range of material compositions and properties efficiently. Due to this, the printer boasts a number of interesting features for researchers.

The most notable feature of this printer is its “Hexa Powder Feeder” system, which allows for the precise control of up to six different material ratios during experiments. This system ensures accurate powder feeding, even in micro-amounts, making it ideal for detailed and precise research applications. For example, it is optimized for High Entropy Alloy (HEA) research. The feeder is able to speed-scan alloys of various compositions during 3D printing, enabling material research to be carried out quickly.

The features of the MX-Lab 3D printer are primed for alloy research as shown in this image

Other features include auto powder calibration, an automatic adjusting of the z-layer, the ability to set the appropriate laser powder for the material at the desired location for multi-material samples and a monitoring system. The latter monitors parameters like laser power, melt pool image, coordinate system and powder feeding system, providing data extraction capabilities for the user. A huge boon when it comes to research.

Using DED 3D Printing for Material Research

Looking at its features, it is understandable why MX-Lab 3D printer has been making some waves in the material research sector. Indeed, already 40 units have been sold in 15 countries worldwide including the USA, Europe and of course Asia. And the use cases show that it is very well-suited to material research in particular.

Take the example of HEA research, alloys that are formed by mixing equal or relatively large proportion of five or more elements. These alloys tend to have higher strength, higher hardness and a high corrosion resistance compared to standard alloys and metals.  This makes them particularly attractive in fields like mold manufacturing, aerospace, anti-radiation and more. And it is one of the more popular ways that researchers are using the MX-Lab 3D printer, for example at KAIST in South Korea.

Some of the research topics that have been explored using the MX-Lab 3D printer from InssTek

Further applications can be seen over a number of prestigious research institutions. For example, in the USA, Brown University is using the MX-Lab 3D printing for innovative research in materials science and engineering. At the University of Michigan meanwhile, researchers have been conducting studies on high-performance alloys and 3D printing process optimization. Then at the University of North Dakota, the MX-Lab is being used to develop multi-material structures and machine learning applications in 3D printing.

Applications in other countries, including at the VTT in Finland where they are working on finding an improved alloy by changing the composition of an existing alloy. Finally, COMTES FHT a.s. in the Czech Republic is using the 3D printer to make FGM samples.

Standing for Functionally Gradient Materials, these are remarkable for their ability to include variation in composition or microstructures over volume, thus allowing for changes in the properties of the material and allowing them to be designed for specific function and applications. Only 3D printers like the MX-Lab would be able to create them. Numerous publications in esteemed journals have also showcased the versatility and high performance of the MX-Lab in various research domains.

An InssTek spokesperson concludes, “The high interest and trust in MX-Lab’s performance and potential from research institutions are driving our success in the global market. We aim to continue partnering with more institutions to contribute to innovative technology development.” You can learn more about the MX-Lab 3D printer HERE. And be sure to check it out at Formnext at Booth D98, in Hall 12.0 if you are interested in seeing directly how it can be used for material research.

What do you think of the MX-Lab 3D printer and its applications in material research? Let us know in a comment below or on our Facebook and Twitter pages! Don’t forget to sign up for our free weekly Newsletter, with all the latest news in 3D printing delivered straight to your inbox!