Hoffman Estates, Illinois – DMG MORI and Schaeffler AG are developing a process to use additive manufacturing to make roller bearings. Schaeffler engineers are using a Lasertec 65 3D hybrid machine to develop the process.
The machine offers laser deposition welding, enabling it to build components from powdered metal, following by machining. So additive and subtractive steps can be done in a single setup.
The Lasertec 65 3D hybrid uses two powder feeders and enables targeted control of the changeover from one material to another during laser deposition welding. This results in graded materials with a smooth transition between the different material properties. The toughness and hardness of the material can be regulated in the build-up process and optimally aligned to the specific requirements of the individual application.
Schaeffler and DMG MORI are testing suitable materials in the cooperation project, with the aim of advancing the development of additively manufactured rolling bearing components in small batch sizes.
Schaeffler engineers also hope to use the machine for development of electric racing car components for the Formula E electric race series. Material gradation could allow the deposition of magnetic and non-magnetic materials. Because electric motors use magnets so extensively, creating parts with adjustable levels of magnetic particles could be valuable for electric vehicle components.