There’s no magic. It’s just the future.

Conify harnesses the power of Design for AM techniques to add engineering value to a product along with powder recycling strategies to boost manufacturing quality and efficiency, all while promoting environmental sustainability and fostering economic resilience.

Metal Powder Characterization, Specification & Re-Use Methodologies

  • Extensive investment on state-of-the-art equipment

  • Material analytics and digitised materials’ database

  • ‘Earmarking’ process on all steps of powder handling

  • Tailored powder refurbishment and up-cycling protocols

  • Assessment of economical and technical impact

The developed methodologies for metal powder characterization, specification, and re-use in metal additive manufacturing include several essential steps. These steps encompass chemical composition and purity analysis, tap density and flowability testing, shape and size analysis, and particle morphology imaging. Powder recovery plays a critical role in ensuring process sustainability, and recycling methodologies are implemented to extend the lifespan of powder production and use. Tailored powder refurbishment and up-cycling protocols are formulated to enhance powder quality and enable efficient reuse. The economic and technical impact of these methodologies is examined to improve process process sustainability.

Commercial metal alloys & Custom Powder Benchmarking

  • Printability & Feasibility studies: process development and optimization for a wide variety of commercial metal alloys
  • Custom metal powder feedstock
  • Assignment of process parameters for custom alloy powders to improve build microstructure and performance
  • On-site support for custom material validation

Conify invests in R&D activities to continuously update its database of developed process parameters for commercial metal alloys. Comprehensive characterization protocols are established to define the best material-process parameter pairs. Conify, along with its trusted collaborators, provides methodologies aimed at improving the quality and performance of the final products by adjusting the powder composition, characteristics, and printing parameters to achieve the desired microstructural properties. This process ensures that the printed parts meet the required performance criteria and improves the overall quality and efficiency of the manufacturing process.

From subtractive to additive manufacturing

  • Material selection for AM
  • Part (re-)engineering and process planning for prototyping
  • Topology Optimisation
  • Numerical analysis & simulation
  • Post-AM quality inspection

Material selection for additive manufacturing (AM) involves choosing materials based on their properties and suitability for the intended application, considering factors like mechanical properties, thermal stability, and compatibility with the AM technology used. Part (re-)engineering and process planning for prototyping include redesigning parts to optimize them for the AM process by assessing key aspects such as functionality and geometrical features and planning the process to ensure successful prototyping. Topology optimization is a computational technique used to optimize the material layout within a given design space, aiming to maximize performance while minimizing material usage, resulting in lightweight and efficient designs. The results are verified through numerical analysis and simulation which predict the part’s behavior, helping to optimize the design to achieve desired outcomes. Post-AM treatment quality inspection involves inspecting the quality of the parts produced through AM to ensure they meet required specifications, including various testing and inspection methods to verify the integrity and performance of the final product. This step includes necessary heat treatment for stress relieving and annealing, post-treatment (machining, sand blasting etc.) as well as the verification of mechanical properties and evaluation of surface roughness, and dimensional accuracy through 3D laser scanning on 3D printed parts.