By Evan Butler-Jones,
Vice-President, Product & Strategy

 

NExP-1 aluminum for additive manufacturing is going to re-frame many materials selection discussions.

The difference between Equispheres’ NExP-1 and a competing material is clear. NExP-1 has much less dust and packs more densely.Industry organizations and major manufacturers have made it clear that less hazardous materials are a critical enabler for the broader adoption of additive manufacturing. Now, organizations that were unable or unwilling to use aluminum can do so with significantly less need for extensive (and expensive) storage and handling precautions.

Equispheres’ NExP-1 aluminum printing media is a less hazardous option for production printing of high-quality parts. It has been designed to be non-explosible and non-combustible under standard test conditions, providing clear operational benefits for additive manufacturing facilities in addition to the safety advantages.

This article will cover the handling characteristics of NExP-1 and what this means for additive manufacturing facilities, plus its printing parameters for laser powder-bed fusion.

Non-explosible NExP-1 vs. conventional aluminum powders

At the root of every industrial safety program is the truth that eliminating the hazard is the first and most effective step in improving workplace safety.  While NExP-1 cannot eliminate all the hazards related to powder handling in an industrial environment, it removes one of the most significant.

Beyond the safety benefits offered by NExP-1, there are significant operational benefits that come from using a dust-free material feedstock.

NExP-1 is suitable for facilities where materials handling and storage of materials at risk for dust explosions is either undesirable, cost prohibitive or proscribed by regulations, such as mixed manufacturing environments, universities, secure facilities or extreme environments.

NExP-1 can go where other aluminum materials can’t. It allows the industry to completely re-think where 3D printing of aluminum can occur. It positions aluminum as an option for additive manufacturing of automotive, aerospace and defense applications.

Beyond the peace-of-mind that comes with using NExP-1, there are significant operational benefits that come from using a dust-free material feedstock.

Since NExP-1 has proven to be non-explosible and non-combustible, companies may be able to avoid the cumbersome and expensive protocols for explosive dusts, subject to the regulations of each jurisdiction.

Per the guidelines issued by the National Fire Protection Association in the United States the non-explosible, non-combustible nature of NExP-1 means that the need for dust hazard analysis related to raw powder handling may be eliminated.  Consequently, this reduces the need to invest in specialized handling equipment and safety systems required for explosive dusts. NExP-1 can use existing powder storage areas.

Depending on local regulations, costs associated with explosion-related facility certifications may also be eliminated.

It is important to note that NExP-1 does not eliminate the need for safe handling practices and does not eliminate all risks. For example, the laser powder bed fusion (L-PBF) process by its nature produces fine particulates that are captured in the filters of industrial L-PBF machines.  Using NExP-1 does not eliminate the production of these fine particulates, and so filter handling must always follow manufacturer recommendations.

In addition, organizations using multiple materials in their AM processes must be wary of the reactivity potential resulting from mixing materials.  NExP-1 does not eliminate the need for good industrial hygiene practices.

For facilities already accustomed to handling aluminum, NExP-1 offers:

• More streamlined handling and transportation of materials
• Reduced infrastructure and overhead expenses
• Lower burden of regulatory documentation
• Reduced cleaning time versus competitive products

The unique surface properties and lack of dust make this material faster and easier to clean off equipment and parts after printing. Operators will notice it sticks less to surfaces and makes machine clean up easier. This can improve productivity and increase machine uptime.

The high sphericity, lack of dust, and unique particle properties make this material faster and easier to clean off equipment and parts after printing. Operators will notice it sticks less to surfaces.

Lower the risk of dust explosions

Aluminum powders with a particle size of 420 microns or less generally present an explosion and combustion hazard, and therefore require specialized storage and handling procedures (Recommendations for storage and handling of aluminum powders and pastes, The Aluminum Association).

NExP-1 does not have the same explosion risk as typical aluminum powders. It has been tested and found non-explosible, per ASTM E1226, Standard Test Method for Explosibility of Dust Clouds. The material is also non-combustible, per the UN Manual of Tests and Criteria, Part 3, Subsection 33.2.1. for flammable solids.

We have achieved a safety breakthrough with a material that is still compatible with L-PBF equipment, printing at typical layer heights with excellent density and surface quality.

Safer material for laser powder-bed fusion

NExP-1 is an unmodified material without additives or coatings. It maintains the AlSi10Mg composition that is well-known by the industry, achieving a safety breakthrough without sacrificing productivity.

The material’s safety characteristics are the result of the unique capabilities of Equispheres’ technology and the company’s commitment to support broader adoption of additive manufacturing through materials innovations.

NExP-1 is designed to be printed on laser powder-bed fusion equipment at typical layer heights (60 um and above). It is ideally suited for high-productivity applications and high-powered (700W and above) L-PBF machines, providing excellent density and overall quality. Recently, Equispheres and Aconity3D  achieved build rates about 9x greater than industry norms with NExP-1, using an exceptionally high-powered laser and beam shaping.

With virtually no fines or dust, and providing exceptional flow, NExP-1is a completely unique printing media, unlike other aluminum powders for 3D printing. One of the intangible benefits it provides is the peace of mind granted by the lower risk of combustion, explosion, damage to facilities and injury. Globally, in 2021, there were 216 industrial combustible dust incidents (Dust Safety Science, 2021 Report).

NExP-1 is the answer to safer, cleaner, faster additive manufacturing of aluminum parts. It is a significant improvement over competing metal AM materials. This new engineered powder is able to produce high-quality parts at high throughput rates, with a better safety profile.

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