Cambridge-based TWI Ltd, an independent research and technology organisation, has ordered a five-axis Trumpf TruLaser Cell 7040 with a disk laser and a laser metal deposition (LMD) capability for its facility on the Advanced
Manufacturing Park (AMP) in Rotherham.

Due to arrive this summer, the machine will be put to work on the Open Architecture Additive Manufacturing (OAAM) project at the AMP facility, for which TWI is the lead partner.

Due to run for three years, this project aims to develop directed-energy deposition (DED) additive-manufacturing (AM) technologies that can be scaled up to handle large components — for the benefit of UK aerospace companies.

The TruLaser Cell 7040 will feature several important modifications, and Trumpf has worked in close co-operation with TWI to deliver a system that will meet the specific requirements of the OAAM project.

For instance, the 1m Z-axis capacity will be extended to 1.5m in order to accommodate large aerospace parts (along with a 4m X axis and a 2m Y axis).

In addition to the system’s five-axis capability, there will be a fully integrated rotate-and-tilt table with a 1,500kg load capacity, controlled by special software routines specified by TWI and being developed by Trumpf (www.trumpf.com).

There will also be support from Autodesk, which is developing common CAD/CAM control interfacing across the OAAM DED technologies.

The modularity of the TruLaser Cell will also enable TWI to integrate additional process steps, such as non-destructive inspection systems.

Carl Hauser, TWI laser additive-manufacturing section manager, said: “The OAAM project will steer the development of large-scale 3-D printed aerospace parts — typically aerospace body and fuselage components, but also engine casings and landing-gear parts, for example.

"The new Trumpf machine will be an integral and critical resource to drive our organisation forward, not just on the OAAM project, but for many years beyond.”