What did we make? A full-thickness Ultrasonic Additive Manufacturing (UAM) part with a barcode that is undetectable and impossible to counterfeit.
These parts were made for Pacific Northwest National Laboratory. It is a UAM through-thickness barcode that is both undetectable and impossible to counterfeit. This part is an example of additive manufacturing for technology protection. The part can be interrogated to determine that the device has not been altered or tampered with. In addition to the custom alternating layers of two different metals, 110 copper and 6061 aluminum, this part also has embedded sensors.
Fabrisonic CEO Mark Norfolk sits down with Brandon Ribic from America Makes to talk 3D Printing.
Video highlights include discussion on the trending use of multiple processes, such as Ultrasonic Additive Manufacturing coupled with Powder Bed. Fabrisonic, which recently doubled in company size, is also seeing interest in embedded electronic sensors in solid metal for uses such as product health monitors and IoT implementations and build plates for powder bed. Also, trending interest in metal cladding of dissimilar metals.
As Fabrisonic approaches its 10-year anniversary, I am reflecting on the variety of accomplishments that Fabrisonic has achieved with ultrasonic additive manufacturing (UAM). UAM is a 3D metal printing technique that uses sound instead of heat to join metal.
In our short ten years:
Commercialized four standard 3D printing machines, as well as numerous custom systems
Over 35,000 3D printed parts including components for satellites, nuclear reactors, and aerospace applications
Innovations such as the embedding sensors in the Smart Build Plate to help with in situ process monitoring of powder bed fusion equipment
Proven out numerous novel material combinations based on UAM’s solid-state nature combining different metal alloys, metal matrix composites, even amorphous metals
Recent Government contracts such as America Makes project to help develop MMPDS design allowables for 6061 and a NASA SBIR to develop UAM for use in orbit
Today we turn the page with a new product launch outside of the world of 3D printing. Don’t worry, we are still religious proponents of 3D printing even as we expand to other large growing markets. We will continue to serve our UAM customers and expand UAM research, development, and capabilities.
However, as we’ve grown, we have found that there is tremendous demand not only for UAM but for high-powered ultrasonic welding in general. So today, we launch the SonicLayer® X̅ Seam Welder. This seam welder is faster, has wider welds, and the ability to join more layers in a single pass than any existing seam welder on the market. Leveraging years of experience in 3D printing, our seam welder simply does more.
The X̅ or X-bar is the seam welder under the Fabrisonic SonicLayer® brand. The seam welder’s name comes from the Roman numeral for 10,000 as our high-powered seam welding has 10,000 watts of power.
As a seam welder, the SonicLayer® X̅ is a technology that can be used in many applications. This includes continuous tube and seam, solar panels, battery anode/cathode tabbing, and connectors. By repurposing the patented high-powered ultrasonic devices developed for UAM, Fabrisonic can provide a seam welder with twice the power of current market seam welders.
There are numerous benefits:
Up to 250 inches per minute
Up to 0.040 inch (1mm)
Capable of Aluminum, Copper, Stainless, Nickel alloys, and even Metal Matrix Composites
Up to 2,300 pounds (10,000N)
Up to 1.063 inch (27 mm)
Join more layers in one pass
The SonicLayer®X̅seam welder has successfully manufactured a variety of electrical grade foils for interconnects, batteries, and flexible shunts as well as welding dissimilar metal combinations such as Cu/Ag, Cu/Al, Al/Fe. In addition to high-speed production of electrical systems, high-power seam welders can be used for metal foil packaging, sheet metal welding, cladding, and selective reinforcement. The SonicLayer® X̅seam welder can be used in any application needing to join metal foils or sheets together. Use this technology to join multi-material combinations of a vast array of metals and metal matrix composites.
Is it any wonder our taglinefor this product is X-Bar: When You Need Extra Power!