ADDITIVE MANUFACTURING

Since our founding in 1943, Imperials capabilities have continually grown and adapted
according to the needs of our customers, the changing marketplace, and advances in
technology. It is this focus on new approaches that led Imperial to become an early adopter
of CNC machining way back when. As a result of our bold outlook on new technologies, we
ventured into the world of Additive Manufacturing (AM), specifically Powder Bed Fusion, in
2013. While Imperialand manufacturing in generalhas always followed the subtractive
model (SM) of manufacturing (starting from something and reducing it by cutting, punching
or forming), AM (starting from nothing and building it layer by layer into a completed product)
provides endless opportunities in fabrication that are not possible via Subtractive means.

OUR AM PROCESS & MACHINES

We chose the SLM 280 HL and Powder Bed Fusion as our initial foray into metal 3D Printing
because it yields complex structures built to close tolerances. Close tolerance complex parts
have been Imperials stock in trade for many years. We have always been willing to tackle
extremely challenging and difficult tasks and the addition of our SLM 280s to our equipment
portfolio gives Imperial the ability to build parts that we have never been able to build before.
We recently added our second SLM 280 machine tool with dual lasers; this allows for more
flexibility and faster build times.

Selective laser melting on SLM-280 HL

The SLM-280

Dual lasers in operation (view of 3D build underway)

While having AM equipment is clearly a prerequisite for an effective AM approach, having

the ability to seamlessly marry both Subtractive and Additive approaches gives Imperial
a unique capability not found in most Additive shops. Almost all additively manufactured
structures require further subtractive processing, and making allowances for those subsequent
operations during the AM design process enables Imperial to yield consistently superior
results.

THE BENEFITS OF AM
While there is plenty of hype surrounding AMand it is by no means the process of choice for
many current applications--AM offers very realistic opportunities to improve on current designs. Of
particular interest to Advanced Manufacturers and those on the leading edge of development are
several specific design cases where AM should be considered:
Small weldments and assemblies can be combined into a single structure,
eliminating welds as well as BOM items. This results in lower fabrication,
testing, and inventory costs.
Internal shapes and features can be printed in place layer by layer, allowing
freedom to route process gases, liquids, and wiring. This enables maximum
flexibility when designing internal features for coolant, vacuum, pneumatic
and/or hydraulic flow.
Complex internal structures
are possible with AM as
shown in this M777 Nut
Prototype

M777
Nu t P
rototinternals
Structures can be built much lighter since AM allows
to be hollow,
ype
semi hollow, or partially supported with shapes that yield the utmost strength.

M777

Nuthe
t Pro
No tooling is required for
AM
process, which
totbuild
ype
rapidly advances delivery timescales for
casting and
forging applications. Prototype and proof of
concepts, in metal, can be fabricated in days
Complex shapes and structures can be
generated that simply cannot be created via
Subtractive means. Features can adopt the most
efficient shape for that specific function. Additive offers true design freedom
when it comes to unique shapes.
Costly materials can be processed more efficiently since the process yields
a near net shape end resultno costly material, removal operations, or useless
scrap is generated.
These are just a few of the benefits of Additive Manufacturing that are readily within reach to todays
Advanced Manufacturing leaders. Seven decades of experience in Subtractive methods, with dozens
of CNC machine tools at our disposal, puts Imperial Machine & Tool Co. in the forefront of this exciting
and dynamic field. We adopted the technology readily and have been actively hiring engineers and
AM professionals to support our goal of being a leader in metal additive manufacturing.

8 W. Crisman Rd.

Columbia, NJ 07832

(908)-496-8100