Sinter-based additive manufacturing laboratory

The laboratory covers the entire value chain of the manufacturing process: from component design (including topological optimisation and process simulation), raw material development and validation, and the manufacturing process (printing, debinding and sintering), to post-processing, focusing on improving surface quality and part functionalisation.

The laboratory is equipped with various types of design and simulation software, as well as various printing technologies, including material extrusion (filament, pellets and pastes), stereolithography and binder jetting.

It is precisely the latter that TECNALIA is focusing on, as we currently have two small format printers (ExOne Innovent), a medium-size printer (Z-Corp), and a large format printer (HP Metal Jet S100).

The infrastructure also has the furnaces required to carry out both the organic debinding stage and sintering of the parts.

Sinter-based additive manufacturing processes produce parts with geometries close to final dimensions, minimising the need for subsequent machining. The technologies presented are suitable for the production of single parts as well as for medium series production.

In addition, these technologies allow the processing of a wide variety of metallic and ceramic materials, and even mixtures of both, making it possible to develop products with designs and functionalities that would be impossible to achieve using conventional manufacturing processes.

They also substantially reduce lead time when producing parts, and offer the possibility of mass customisation without additional costs. This is especially relevant in the case of binder jetting technology.

Finally, these technologies offer an ideal environment for research into a wide range of materials, greatly increasing the potential for innovation in multiple sectors.

The laboratory can offer companies differential value at various stages of product development and industrial innovation. Thanks to its technological capabilities, this type of laboratory offers support in the following key areas:

• Optimised component design using advanced modelling, simulation and topological optimisation tools, enabling the creation of complex geometries that are not feasible with traditional manufacturing techniques.
• Reduced lead time thanks to the rapid production of functional prototypes or short series, which accelerates the product validation and commercialisation phases.
• Development of tailor-made materials, including metals, ceramics or combinations of both, adapted to specific sector or application needs, with customised mechanical, thermal or chemical properties.
• Manufacturing of customised parts without cost increase, enabling flexible production strategies or mass customisation, especially useful in sectors such as healthcare, aerospace or consumer goods.
• Support in process validation and industrial scale-up, including printing tests, debinding, sintering and post-processing, ensuring that the transition from lab to plant is as smooth and reliable as possible.
• Technological advice and training, helping companies to integrate these technologies into their own production processes and to train their technical teams.

• Aeronautics and space: product manufacturers, engineering companies developing components and end users.
• Defence
• Automotive industry
• Construction equipment and facilities
• Railway
• Chemical and petro-chemical industry and biorefinery
• Infrastructure
• Machine tool cutting tool manufacturers.

Having advanced and pioneering sinter-based additive manufacturing equipment, and especially with binder jetting technology, is essential for a technology centre such as TECNALIA. However, our laboratory is not only about infrastructure – we also offer you a comprehensive and results-oriented approach:

• A comprehensive service, from the first contact to final delivery, covering all phases of process or product development: component design and simulation, optimisation of the manufacturing process (printing, debinding and sintering), assessment of material and final product properties (microstructure, mechanical and chemical properties, etc.), component validation and cost analysis.
• Technical advice at every stage of development, ensuring full product traceability and adapting to your specific needs.
• Interpretation and detailed explanation of the results: we not only provide data, but also contextualise it to offer you a clear and understandable vision of the work carried out, facilitating technical or strategic decision-making.