your application.
your material.
Made in Austria.
your application.
your material.
Made in Austria.
Our Portfolio.
Advanced material, manufacturing and engineering solutions from Materia Sphere.
Our Portfolio.
Advanced material, manufacturing and engineering solutions from Materia Sphere.
Powder Prototyping.
We offer customized powder materials according to your specifications. Our technologies enable us to produce precise powders from small batch sizes ideal for R&D applications to larger volumes used for productive Additive Manufacturing.
We believe the potential of Additive Manufacturing has not yet been fully tapped into. That’s why we strive to enhance Additive Manufacturing with tailor-made solutions to overcome today’s limitations. Resulting in a more versatile and simplified use of metal-based AM for your production. Experience the world of powders from a new perspective with materials from
MAGNESIUM. ALUMINIUM. TITANIUM. IRON. NICKEL. COPPER. ZINC. YOUR ALLOY.
Case Study #1: EN AW-6061 powder prototype.
EN AW-6061, a heat treatable aluminum alloy, boasts moderate mechanical properties and strong resistance to corrosion from both atmospheric and seawater sources. It possesses excellent weldability and finds applications in architecture, automotive, and railway sectors. However, processing it via LPBF poses challenges due to hot-cracking. Pre-heating can mitigate this but increases machine complexity and may reduce build volume.
In this case, the powder prototype based on EN AW-6061 is modified with a metallic grain refiner, to be trialed for improvements in hot cracking in a powder bed fusion process.
Case Study #2: CuZn powder prototype.
Brass, an alloy of copper and zinc, is widely used in automotive, marine, plumbing, and jewelry industries. It may include other elements like aluminum, iron, silicon, or manganese for specific enhancements such as strength, friction properties, or corrosion resistance. The zinc content affects density, elasticity, thermal conductivity, as well as its color. Typically, brass alloys contain up to 50% zinc; however, exceeding this threshold results in the formation of a γ-phase, which renders the material very brittle.
The CuZn powder prototype pictured features a zinc content of 10 wt.% as a starting point for evaporation correction during processing via LPBF (Laser Powder Bed Fusion).
Case Study #3: CuCr powder prototype.
Copper and its alloys are renowned for their excellent thermal and electrical conductivity, making them vital components in the development of new electronic and heat exchange systems. CuCrNb alloys, notable for their use in aerospace liquid rocket engine combustion devices, excel in harsh operational environments. Strengthened via precipitation hardening while preserving conductivity, they can withstand harsh operational conditions.
The powder prototype consists of 3.25 wt.% chromium with copper balanced, featuring a particle size distribution ready to be tested for material development in a powder bed fusion process.
Tailored Solutions.
Process Engineering.
We develop individually tailored process parameters for your desired materials. Using our data-driven approach we optimize the process on your Additive Manufacturing systems.
Case Study: Aluminium Alloy Process Development
The right parameters are key to a successful LPBF-build job. The most fundamental ones are the Laser Power P, the Scan Speed v, the Laser Beam Diameter σ, and the Layer Thickness t. Together, they express the Volumetric Energy Density (VED), calculated as VED=P/(vσt).
When exploring a material new to additive manufacturing, the relative density of test specimens serves as a key metric for assessing baseline print performance, typically ranging from around 98% to 100% in successful trials. Depending on the objectives, the most promising outcomes from initial evaluations can guide further advancements in quality and efficiency.
This approach leads to finely tuned process parameters that improve part integrity, productivity, and reliability in laser powder bed fusion (LPBF) manufacturing.
Made in Austria.
Design and Manufacturing.
Utilize our know-how in part design and problem-solving for AM. Along with our dedication to innovation and state of the art tools, we develop solutions that drive your projects forward. In addition, our engineering services include additive and subtractive part-manufacturing, bringing your concepts to reality.
Made for AM: Part engineering and manufacturing
Effective use of AM isn’t just about printing any and every component; it’s about strategically designing and optimizing parts to fully leverage the unique capabilities of additive manufacturing. It allows us to create complex geometries, reduce material waste, and optimize performance in ways that traditional manufacturing can’t match.
To make the most of AM, several key considerations are essential. First, Design for AM (DfAM) involves topology optimization and lightweight structures to maximize efficiency and functionality. Second, material selection is crucial: choosing the right materials enhances the strength, durability, and sustainability of the final product. Finally, iterative prototyping enables rapid testing, and refining of designs, ensuring the best possible outcomes.
In our view, the future of manufacturing lies in combining all available methods, enhanced by the comprehensive AM toolbox.
Our tools.
To bring your concept to reality, we have a wide variety of machines and tools for rapid prototyping, post processing and CNC machining, including
2x SLM 280 2.0. SLM 500. 2x Haas UMC 500. Hermle C52 MT dynamic.
Our tools.
To bring your concept to reality, we have a wide variety of machines and tools for rapid prototyping, post processing and CNC machining, including
2x SLM 280 2.0.
SLM 500.
2x Haas UMC 500.
Hermle C52 MT dynamic.