+GF+ Dmp Factory 500 3D Printer

3D SYSTEMS  +GF+ DMP Factory 500
Scalable metal additive manufacturingfor seamless large parts
GF Machíníng Solutíons: all about you
When all you need is everything, it s good to know that there is one company that you can count on to deliver complete solutions and services. From world-class electrical discharge machines EDM ,
Laser texturíng and Additive Manufacturing th ough to first-class Milling and Spindles, Tooling, Automatíon and software systems - all backed by unrivalled customer service and support - we, through our
AgieCharmílles, Mícrolution, Mikron Mill, Liechti, Step-Tec and System 3R technologies, help you raise your game and increase your competitive edge.

+GF+ Making 3D producti
3D Systems is a global 3D solutions company focused on connectíng our customers with the expertíse and dígítal manufacturing workflow required to meet theír busíness, design and engineering needs. From dígitalization, desígn and símulation through manufacturing, inspection and management, our comprehensive portfolio of technologíes provídes a seamless, customizable workflow designed to optímíze products and processes whíle accelerating outcomes. Wíth advanced hardware, software and materíals as well as on demand manufacturing servíces and a global team of experts,
we are on a mission to transform businesses through manufacturíng ínnovation.
Contents Market introduction 4
Meet the AM factory 6
Modular concept for scalability 8
Integrating additíve manufacturing 9
wíth traditional technologies
The vacuum chamber concept 10
3DXpertTM 11
Build higher quality large parts 12
Lower total cost of operation 14
Simplify process workflows 15
Scale in a factory environment 16
Customer services 18
Technical specifications 20
3D systems 22
Redefining the AM Factory
GF Machining Solutíons, a leading global provider of complete The DMP Factory 500 offers manufacturers in aerospace, auto-solutíons to the precísíon machíníng índustry and manufactur- motive,  motorsports and other high-tech industríes íncreased ers of precisíon components, and 3D systems, a leading global productivíty, part quality and process safety while significantly provider of additive manufacturing solutions and the píoneer reducing Total Cost of Ownership TCO and facilitating seam-of 3D printing, have partnered to introduce new metal 3D less íntegration of inetal AM technology into the entire manu-príntíng solutíons that empower manufacturers to develop facturing chain. their own dedicated Addítíve Manufacturing AM factories.
Metal AM today is poised to delíver sígnífícant productíon benefïts to orígínal equípment manufacturers OEMs . Advances in additively- manufactured aerospace parts have shown how thís technology can now be deployed to all metals manufacturers.
By leveraging that experíence, consequently, OEMs aгe now ready to fully deploy and experíence the benefıts of thís game-changing technology.
Metal AM has delívered a natural evoiutíon to the aerospace índustry because it:
Optímízes buy-to-fly ratios through reduced cost of waste materíal
Optimízes geometry and desígn for functíonalíty to reduce weíght and increase performance
Reduces product development and production tímes to better serve a fast-changing market
Gf Machíníng Solutions, wíth íts long hístory of relationships with OEMs, and 3D systems, the global addítíve manufacturing soiutíons company, wíth the deepest expertíse and broadest portfolio of 30 printers, are the ideal partners for developing factory-grade AM solutíons that will fully address the
challenge of mass productíon, wíth complete process traceability as requíred from the aerospace índustry.
Scalable metal additive manufacturing for seamless large parts

Integrating AM with traditionai technologies
To underlíne our mutual commitment to províding ínnovatíve solutíons to market leaders, GF Machining salutíons has fíled a
patent applícatíon for a new carrier concept. Thís flexible solu-tíon allows the user to position and locate build plates on the RPM and provides links to automated conventional machiníng processes. Thís concept contributes to a signífícant íncrease in automation possibilities and reduction of build plates costs.
Automatíon of the AM process is a top priority, but we are also keenly developíng solutions to seamlessly integrate AM technology ínto the complete manufacturing process chain. The DMP Factory 500 dríves effficient management of post-processíng steps alongsíde your metal additíve production process, such as wíre-cuttíng electrícal discharge machíning EDM and millíng.
System 3R carríer concept for easier post-processíng
Integrated System 3R chucks
Carrier concept
The vacuum chamber concept
3D Systems has developed a unique vacuum chamber for the PTM to improve process efficíency and part quality and reduce overall manufacturing costs in metal AM. In order to consistently achieve these benefits throughout the workflow from prínting to material recycling, the resulting inert environment is also present ín other modules of the DMP Factory 500.

The DMP Factory 500 is a workflow-optimized metal 3D printing solution for massive scalability, repeatable high-quality parts, high throughput, and low total cost of ownership (TCO), capable of producing parts of up to 500 x 500 x 500 mm in size. This advanced metal production system is powered by proven precision metal additive manufacturing technology, along with 3DXpert™ software, LaserForm materials, Direct Metal Printing (DMP) production modules, and expert application support from GF Machining Solutions.

Companies that have identified a desirable metal additive manufacturing (AM) application in an in-house laboratory setting will realize the complications of scaling with a stand-alone printer. Very often, the costs and human resources required make this an unrealistic approach for volume parts production. To develop a viable factory solution, it must be possible to control part quality, cost, workflows, and to scale operations easily.

The DMP Factory 500 enables users to:

Build higher-quality large parts

Lower TCO

Simplify process workflows

Scale in a factory environment

Modular Concept for Scalability

The DMP Factory 500 is a scalable manufacturing solution composed of function-specific modules designed to maximize efficiency by optimizing utilization. Each module of the DMP Factory 500 is fully integrated with a sealed Removable Print Module (RPM) that delivers a controlled print environment. It is engineered to move between the printer and powder modules for a continuous production workflow. Customers can configure a custom metal AM factory by selecting the right combination of modules to optimize their specific production needs.

Modules Overview

Printer Module (PTM)
Designed for the ongoing, 24/7 printing of parts.

Transport Module (TRM)
Efficiently transports RPMs between the printer and powder management modules using a precision positioning system, facilitating easy loading of RPMs into both PTM and PMM modules.

Powder Management Module (PMM)
Efficiently depowders parts on build platforms under inert conditions, automatically recycling unused powder materials, and preparing the RPM for future print jobs.

Parking Module (PAM)
Provides interim storage of RPMs in an inert environment until they are ready for further progression in the workflow. It stores a fully prepared RPM for its next print job while the PTM is finishing the previous one.

This modular approach allows for scalability and enables a continuous production workflow, making the DMP Factory 500 an ideal solution for manufacturers seeking to scale their metal additive manufacturing processes efficiently.

The DMP Factory 500 offers a solution that not only maximizes efficiency but also optimizes the quality and performance of metal 3D printing. One of its key features is the low oxygen (O₂) content in the build chamber, which significantly reduces the Total Cost of Ownership (TCO). This is achieved by protecting the powder from degradation due to exposure to oxygen, which could otherwise affect its chemical composition and increase moisture content. By minimizing the exposure of materials to oxygen, the system ensures optimal operating conditions, which is crucial for maintaining consistent mechanical properties in the printed parts. Additionally, the DMP Factory 500 helps maximize the utilization of LaserForm metal alloys during manufacturing, resulting in higher efficiency, shorter setup times, and fewer material changeovers compared to competing products.

3DXpert: Integrated Software for Metal AM Workflow

3DXpert, the software that powers the DMP Factory 500, is a comprehensive tool designed to handle the entire additive manufacturing (AM) workflow. It allows for complete control over the preparation and manufacturing process, making it easier to transition from a 3D CAD model to a successfully printed part. 3DXpert optimizes the entire workflow from design to post-processing, helping to:

Prepare and Optimize Designs: Import data, modify structures, and position parts for optimized printing.

Simulate and Calculate: Set build strategies and simulate print operations to identify and eliminate potential issues before printing begins.

Send to Post-Processing: Streamline the transition to post-processing with calculated and optimized print operations.

Key Features of 3DXpert Software:

Multi-Laser Control: Intelligent multi-laser control ensures the best utilization of multiple print heads, balancing printing volumes and minimizing errors. This results in high throughput production of multiple or large parts, achieving optimal material properties and surface quality.

Hybrid CAD: A hybrid CAD approach provides greater agility, quality, and speed, enabling changes at any stage of the design and production process.

Simulations and Optimization: Built-in simulation tools minimize trial and error, optimizing print strategies to shorten print time while ensuring part quality.

Efficient Print Strategies: Specific print heads can be assigned to particular zones, helping eliminate seam lines, internal weak points, and material splits.

Seamless Scanning and Consistent Low O₂ Environment

Oxygen-Free Printing: The consistently low O₂ environment in the PTM (Printer Module) and the inert environments in the RPM (Removable Print Module) and PMM (Powder Management Module) ensure that powder quality remains high and parts are printed with optimal material integrity. This is essential for printing highly reactive alloys.

Intelligent Scanning and Laser Control: The DMP Factory 500 utilizes precision laser quality control and in-line verification capabilities, which ensure that the print settings are accurate throughout the entire process. Users can perform in-line scanner calibration checks to monitor laser precision during the build of large parts.

Monitoring and Real-Time Process Data

DMP Monitoring Tool: The DMP Monitoring system provides real-time, in-build data collection and visualization, giving users unprecedented control over their AM process. This toolset allows for:

Real-time process monitoring, providing synchronized images of the melt pool and powder bed.

Post-build process analysis, enabling users to fine-tune their processes for future jobs.

Build parameter optimization to enhance part quality and reduce waste.

This integrated system of software, hardware, and monitoring tools ensures that users can consistently produce high-quality metal parts, optimize their production workflow, and reduce both setup times and material waste, making the DMP Factory 500 a powerful solution for large-scale, precision metal additive manufacturing.

Lower Total Cost of Ownership (TCO)

The DMP Factory 500 solution is specifically designed to reduce TCO and final per-part costs through its modularity and optimized workflow. By tailoring the factory setup to match the specific application and capacity needs, manufacturers can efficiently utilize each module. This modularity also ensures that the workflow integrates smoothly, including post-processing steps. By minimizing waste and scrap, the DMP Factory 500 optimizes part costs and TCO, while enabling consistent production of high-quality parts.

Key Features Contributing to Lower TCO:

High Printer Utilization: The DMP Factory 500 is designed for 24/7 operation, enabling continuous, high-quality printing with minimal downtime. The modular configuration ensures that each Printer Module (PTM) can be utilized efficiently, enhancing productivity and reducing costs.

High Powder Recyclability: The vacuum chamber and inert environments (in PTM and Powder Management Module (PMM)) protect the powder from quality deterioration, allowing for nearly 100% powder recyclability. This significantly reduces the need for new powder, saving costs.

Optimized Productivity of Three High-Precision Lasers: The intelligent print strategies enabled by 3DXpert allow the system to optimize the productivity of three high-precision lasers, ensuring efficient use of resources and reducing time spent with lasers inactive.

Fast Bidirectional Recoating: The high-performance bidirectional recoating system ensures that fresh powder layers are deposited efficiently, increasing productivity by reducing inactive time for lasers.

Simplified Process Workflow

The DMP Factory 500’s integration of hardware and software allows for a streamlined and efficient workflow, minimizing time and effort required to produce quality parts.

3DXpert Software: The all-in-one software provides complete control over every step of the additive manufacturing workflow, from design to post-processing. The CAD-based build setup allows engineers to make edits at any stage without switching between different software programs, increasing agility and reducing delays.

Modular Design for Automation: The system’s five function-specific modules can be tailored to the customer’s requirements and gradually leveled up to a fully automated factory system. This modularity enables the integration of automation in stages, providing flexibility as production needs grow.

Integrated 3R Referencing and Clamping System: The 3R clamping system is optimized for Powder Bed Fusion (PBF) processes, linking to subsequent machining processes and reducing setup and changeover time. This enhances efficiency, enabling production at a larger scale.

Scalability in a Factory Environment

The DMP Factory 500 is built to grow with production demands. It offers a scalable solution that adjusts to increased throughput while maintaining flexibility to configure the modules according to specific requirements.

Optimized Mix of Modules: The flexible architecture enables customers to select and configure the function-specific modules that best suit their production requirements. This customization ensures that the system delivers maximum Overall Equipment Efficiency (OEE), achieving high performance across manufacturing KPIs.

Powder Containment and Traceability: The RPM (Removable Print Module) system keeps powder contained between prints, preventing any powder from remaining in the printer or PMM. The system ensures traceability of powder by tracking the batch numbers and recycling activity, ensuring consistency in material quality across the production process.

Safety and Compliance

The DMP Factory 500 is designed with safety in mind, meeting the highest industry standards.

Safety Standards Compliance: All modules comply with the highest safety standards, ensuring safe operation throughout the workflow, including powder handling in an inert atmosphere.

Inert Atmosphere for Safety: With filter changes taking place in a safe manner, the system minimizes safety risks associated with metal AM solutions. The inert atmosphere used in both the printing and post-processing stages contributes to safe and reliable operation.

Data Connectivity and Enterprise Resource Planning (ERP) Integration

The DMP Factory 500 ensures smooth connectivity with all major ERP systems, enabling easy access to job reports, user logs, execution status, and parameter changes. This simplified traceability allows manufacturers to monitor production in real-time and maintain effective factory management.

The DMP Factory 500 is a comprehensive solution that maximizes TCO reduction, improves productivity, simplifies workflows, and enhances scalability for metal additive manufacturing. Its modular, flexible design ensures it can meet the growing demands of industries requiring high-quality, high-throughput metal parts.

Customer Service & Support

To successfully adopt metal additive manufacturing (AM) and scale your production, partnering with an experienced provider is essential. 3D Systems offers a comprehensive suite of services through their global network, ensuring a smooth adoption process and ongoing operational support.

Customer Innovation Centers (CICs)

3D Systems’ Customer Innovation Centers (CICs) in Belgium and the USA offer invaluable knowledge transfer and hands-on experience. These centers provide the following:

Application Development Support: Experts assist in applying DMP technology to meet specific manufacturing needs.

Testing and Training: CICs offer thorough testing of applications and training to ensure teams are well-prepared for operational tasks.

Ongoing Support: 3D Systems offers continued support, helping customers scale and optimize their additive manufacturing processes over time.

These centers are equipped with a wealth of experience, including application-specific cost-saving solutions, optimizing production workflows, and integrating metal additive manufacturing with conventional processes.

Operational and Support Services

3D Systems' global service organization offers a multi-level approach to support:

3D Connect Service: A secure, cloud-based connection for proactive and preventative support.

Field Service Teams: Local teams guarantee smooth installations and provide fast remote or on-site support to address specific requirements and ensure minimal downtime.

With expertise in DMP processes and metal 3D printing, 3D Systems offers customized solutions tailored to your specific additive manufacturing setup and needs, helping ensure high-quality production and operational efficiency.

Key Aspects of Customer Support

Global Footprint of Customer Support Engineers: Technical support is available both on-site and remotely, reducing downtime and providing production assurance.

Experience Transfer: 3D Systems has guided numerous clients through the adoption of DMP technology over the past 12 years, packaging their know-how in training modules for customer teams.

Technical Specifications

DMP Factory 500 Printer Module

Laser Power Type: 3 x 500 W (Fiber)

Laser Wavelength: 1070 nm

Layer Thickness: Adjustable (2 μm - 90 μm)

Build Volume: 500 x 500 x 500 mm

Material Deposition: Tube Silícon

Repeatability: 20 μm

Material Options: Nickel alloys and others on request

Weight: Approx. 8000 kg (including powder)

Space Requirements:

Dimensions: 3010 x 2290 x 2820 mm (118 x 90 x 111 in)

Facility Requirements:

Electrical: 400 V AC, 3-phase

Compressed Air: 4-8 bar (115 psi)

Argon: 8 bar (58-115 psi)

Software and Control Systems

Software Tools: DMP Software Suite + 3DXpert

Operating System: Windows 10 Pro, 64-bit

Input File Formats: Native CAD files, STEP, IGES, ACIS, Parasolids, STL

Network Protocol: Ethernet (RJ-45)

DMP Factory 500 Modules

Powder Management Module: Dimensions: 4050 x 2450 x 3000 mm

Parking Module: Dimensions: 1450 x 1780 x 1850 mm

Removable Print Module: Dimensions: 1120 x 850 x 1400 mm

Transport Module: Dimensions: 850 x 1810 x 1400 mm

Additive Manufacturing Solutions

3D Systems offers additive manufacturing solutions optimized for metal printing (via DMP), plastic printing (through SLS, SLA, DLP, and more), and comprehensive software support for design and production.

3DXpert All-in-One Software: This solution provides end-to-end support for metal AM, from design preparation to production.

Geomagic: Geomagic offers Scan-to-CAD software for reverse engineering and optimized product design workflows.

With extensive global support, expert guidance, and robust technical infrastructure, 3D Systems ensures a reliable path for manufacturers adopting metal additive manufacturing technologies. Their services, software solutions, and technical support are designed to streamline your production processes and deliver consistent, high-quality results.