We deliver on the promise of thin wall surface structures through Additive Manufacturing
Thin wall structures are increasingly a common feature of highly complex designs, ranging from heat exchangers to exhaust manifolds. Alloyed has developed key technology to make designing and fabricating these complex thin wall structures easier, faster and economically competitive using AM.
Complex Gas Manifold / 210mm x 145mm x 110mm with 250um walls. Optimised and manufactured by Alloyed on a Renishaw AM250 in Grade 5 Titanium Alloy.
Surfaces without Limits
Thanks to our patented laser path generation techniques, we no longer have to use manifold models to represent thin wall surfaces. This approach allows us to reduce the models’ complexity and simplify the design process, by bypassing complex fixing and Booleaning operations altogether.
CAD Model of Complex Gas Manifold / Manifold geometry (left), Non-manifold geometry (right).
97% less model data
using non-manifold data versus manifold data
No mesh operations
removes the need for common mesh operations
Mesh model of section of Gyroid Structure / Mesh triangles coloured depending on exposure parameters used.
High Detail Structures
Alloyed makes it possible to create sub 150um walls using a variety of materials. We do this by controlling the scan path and exposure settings down to each individual mesh face on a surface. This approach also allows us to achieve greater detail by locally grading thickness in each structure.
SEM of Fine detail Gyroid Structure / Wall thickness below 150um. Images courtesy of researchers at Univeristy of Technology Sydney
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