Technical Details:
Metal Additive Manufacturing
Precision You Can Count On
Imperial Machine & Tool Co. is AS9100D certified, ITAR Registered, and has a state-of-the-art Quality Laboratory to ensure the highest levels of quality in the industry.
We have a deep technical understanding of the measurement and analysis of Additively Manufactured components.
Our traditional metrology equipment includes a full array of CMM machines, metrology software, and advanced optical equipment.
In addition to our traditional quality laboratory, Imperial has a comprehensive powder characterization and material analysis laboratory.
To analyze additive manufacturing materials we offer Powder Particle Size Analysis meeting ASTM B822, ISO 13320-1 and other industry guidelines, Light Element Analysis meeting ASTM E1019, E1941, E1447 and other industry guidelines, X-ray Fluorescence Spectrometry for both powder and solid metal samples meeting ASTM E539 and other industry guidelines, and 100kN Tensile Testing meeting ASTM E8/E8M, E4, E83 and other industry guidelines. We can also rely on our Kaiser Aluminum corporate testing resources which include fatigue, impact, creep and stress rupture testing.
We verify powder feedstock and printed metal alloys to the following ASTM AM-Powder Bed Fusion specifications:
Ti6Al4V - ASTM F2924-14
AlSi10Mg - F3318-18
316LSS - F3184-16
17-4PH SS - SAE AMS5643V
Inconel 718 - F3055-14a
Inconel 625 - F3056-14
CoCrMo alloy - F3213-16
Metal AM Production Components, inside Imperial’s Metal AM lab
Production Parts
Imperial operates a highly organized production and quality management system, and is well suited to deliver production quantities of complex 3D printed parts.
With a highly advanced software scheduling system, Imperial is able to closely monitor all key metrics related to the quality of AM builds in real-time, and track production progress.
Delivering on strict schedules is common practice. We excel at managing short-turn development programs and just as nimbly we excel at managing large production programs. Every single job that goes through our AM department travels with a complete technical data packet to ensure smooth production and delivery.
In-house Design Expertise
Imperial has a highly experienced design team ready to collaborate with customers to help optimize their designs for additive manufacturing.
Our design team is led by an engineering PhD; an expert in Thermal Dynamics. He brings over 2 decades of experience in the semiconductor industry, and has particular insight into thermal exchange and fluid flow applications as they relate to metal additive manufacturing.
We are highly capable of working with your design team to develop sophisticated AM-based heat exchangers. Provide us with an input, an output, and an envelope, and we can optimize a heat exchanger to meet your design requirements.
Cross-section cut showing Internal Channels and Thin-Wall features
Our AM team also includes an engineer with a Masters Degree in Additive Manufacturing and Design, and a number of highly trained technicians. We can collaborate with your design team leading to manufacturing ease, and performance improvements.
Imperial has the advanced design and simulation software required to bring groundbreaking designs to life including:
CAD Modeling Software
Solid Works
Pro E Creo
Autodesk Inventor
Autodesk Fusion 360
Additive Manufacturing Software
Magic
Inspire
Auto Fab
SLM Build Processor
Simulation Capability
Fluid Velocity Field
Pressure Drop
Multi-Phase Heat Transfer
Component Stress Analysis
Fluid velocity distribution through a heat exchanger core as a function of water flowrate
Left image: 1.0 liter/min; Middle image: 4.0 liter/min; Right image: 8.0 liter/min
The blue arrow on the left of the image indicates the flow direction
A 3D Printed Inconel component, fixtured into a machining center
Hybrid Manufacturing Experts
Imperial is highly experienced in Precision Multi-Axis CNC Machining, and we effectively combine this experience with our Metal AM capability to deliver components that few organizations in the world are equipped to fabricate.
We operate over 30 precision multi-axis CNC machining centers including 3, 4, and 5-axis milling. Our machines have high spindle speed capability which allows us to efficiently machine AM components made from hard-to-machine alloys like titanium and Inconel.
Our CNC Machining and Metal AM departments are highly integrated, and work together closely to develop effective production strategies. We bring our teams together as we begin all additive projects. The teams recommend design and printing adjustments that will enable more effective CNC machining later on. Most components manufactured by the AM process require some post machining. We understand that, and have built our business around supporting you with that combined capability.
We have a robust vendor network capable of providing all outside processes required including Hot Isostatic Pressing (HIP), other thermal treatments, and specialty metal finishes.
Fast Facts:
Build Volume: 285mm x 285mm x 330mm
(11" x 11" x 13")We fabricate larger AM structures by welding together separate AM components
4 SLM Metal Additive Manufacturing Systems
Powder Characterization Lab
Material Testing Capability
Highly Experienced at Multi-Discipline Advanced Manufacturing applications
Metal 3D Printing + Thermal Conditioning + Precision Welding + 5-Axis CNC Machining + Metal Finishing
Available Materials:
Standard Materials
Titanium
Aluminum
Stainless Steels
Nickel Alloys (Inconel)
These materials are always being processed.
Specialty Materials
We offer a host of other printable materials. Please reach out and we will consider your inquiry for other alloys printable on an SLM platform.
To learn more about Imperial’s Metal Additive Manufacturing capabilities, contact us:
AM Discussion items
Why is AM so impactful to industry and manufacturing overall
Why is AM so beneficial to the markets we pursue?
How long does it take to print a structure
What is our build envelope
Why is machining an important part of a successful AM build program?
Is it easy ?
What sort of programming is required? How do we set up a job to run?
How do we specifically prove out our powders? What kind of equipment do we use to do so?
How much did we invest in AM?
What kind of tools do we have and how many?
How much space do we dedicate?
Importance of Thermal treatment? HIPing?
What about support? Why is it needed and how do we get rid of it? How much of a discussion item is
support with customers and why?
What is our processing environment like? Humidity? Air handling? Auto power backup if loss of power?
What materials are we good at? What materials do we print? Why?
What are competing methods to PBF?
What new equipment do we plan on pursuing?
Peeps to discuss with
Me
Mike Clifford as appropriate on investment etc.
Mike Begarney
Joe Sinclair
The guys who run the equipment
Bob Preg on QC side
Mark Bremmer, Dillan King, other machinists on machining
