Concept Laser Announces New Mlab Cusing R Metal Additive Manufacturing Machine

Concept Laser expands the range to include a new flexible model in a small format with the suffix "R" for titanium applications. The new Mlab cusing R was developed to allow economic fabrication of delicate dental products and medical implants, and for medical instruments made from titanium.

The small machines in the Mlab cusing family allow users to start off in the "flyweight class" of additive manufacturing with metals. Generally, since the Mlab cusing machines were introduced at the start of 2011, they have been opening up the market segment for small delicate components in economic terms. The new Mlab cusing R now also expands the previous range of materials to include titanium and titanium alloys. The clever thing about the Mlab cusing R is the "drawer principle" with what is known as a glovebox module for safe handling of the material. The patented drawer principle from Concept Laser enables a quick change of material without the risk of any contamination of powder materials.

Quality with no compromises

The generative method makes a substantial contribution to improving quality. Cavity formation, rejects and a large amount of reworking, which can arise with the casting method, are now a thing of the past. The Mlab cusing combines a high degree of freedom of geometry, quality and increased material density. Metal laser melting is also a very contemporary method, particularly from the point of view of time: In contrast to the traditional casting method, it offers the advantage that the fully automatic, generative production process can run unattended and overnight. An order can be processed and delivered to the customer the very next day, additive manufacturing with metals means consistently high quality with a short delivery time, and consistent results, time after time.

Change comes as standard – drawer principle allows quick change of material

The concept behind the Mlab cusing R is ideally suited to the production of components with delicate structures made from titanium. It offers a perfect look and structures when a high surface quality and the finest component structures where it matters. The Mlab cusing offers extremely compact dimensions of 705 x 1848 x 1220 mm (WxHxD) coupled with a weight of 500 kg. The clever thing about the Mlab cusing R is the "drawer principle" with the patented glovebox module for safe handling of the powder. The operating principle is extremely practical and simple: The glovebox module is docked onto the machine for the loading and unloading process. The build module can simply be pulled out into the glovebox thanks to the drawer principle. The glovebox is then flooded with argon to inert the chamber, essential for safe titanium processing. The operator accesses the build chamber through the glovebox gloves in order to carry out the loading process or to remove components. After the end of the process, the build module is moved back into the machine and finally the glovebox is undocked. The retractable drawer system is regarded as extremely user-friendly. This includes both the build chamber with dose chamber and the storage container. The drawer system is available in three different build envelope versions: 50 x 50, 70 x 70 and 90 x 90 mm, with the height of the build envelope always 80 mm. The drawer principle enables the use of different build envelopes in a machine. The user can easily exchange the drawers and this ensures flexibility: This offers particular advantages when processing precious-metal alloys because their high material prices mean that it is advisable to use a smaller build envelope. In addition, it is easy to remove the drawers for the purpose of storing materials. Contamination of the powder with oxygen is ruled out because of the component structure in a closed system. The Mlab cusing R is designed in accordance with ATEX directives for safe processing of reactive materials such as titanium and titanium alloys.

The heart of the machine – the laser

The robust and powerful 100 W fibre laser operates with a focus diameter of less than 25 µm in order to reproduce supreme surface qualities and intricate and delicate component structures.

LaserCUSING in XS format with titanium and titanium alloys for the first time

The Mlab cusing R offers a range of ever increasing materials, to include: gold, silver alloys, bronze, cobalt-chromium alloys and stainless steel. New materials which can now also be processed on the machine are titanium and titanium alloys such as Rematitan® CL from Dentaurum, CL41TI ELI (Ti6Al4V) and pure titanium. This increasing variety of material options, make this new machine attractive to different sectors of industry and their specific applications.

Retrofitting is possible

The Mlab cusing machines which are currently on the market can be retrofitted as a customer upgrade. Qualified service engineer install this upgrade package to the machine to level "R", followed by a training session in the handling of reactive materials like titanium and the special safety procedures needed.

Bionics included – LaserCUSING focuses consistently on dental and medical technology

The new Mlab cusing R also expands the previous range of materials to include titanium and titanium alloys, such as rematitan® CL from Dentaurum. One particularly striking characteristic is the high material density, which for the extreme mechanical loads offers advantages over conventional cast parts in dental applications. However, laser fusing also allows bionic structures for use in implant technology. This enables implants to be constructed with a porous structure. As part of this process, cellular structures which support growth into the bone tissue are integrated into the component. Such macroporous surface structures for improving the level of growth into the bone tissue may be used for hip implants, for example. In this field of application, specific, geometric characteristic features can be taken into account in order to allow new functions or functional integration. Depending on what is required, the volume structure of the implant can be adapted to that of the bone tissue in order to ensure that it works durably over a long period of time. Larger machine concepts such as the M2 cusing from Concept Laser are of course also available for larger components.

Increase potential for adding value

If you are currently looking to switch from the conventional milling or casting fabrication of dental or medical implants, as well as delicate and intricate medical components or instruments, the Mlab cusing from Concept Laser provides you with new options in terms of cost calculation and order throughput. The generatively produced component simply has to be separated from the build plate, the supporting geometry removed and then finished. The potential for adding value offered by LaserCUSING is opening up new horizons – now also in an XS format for beginners.

Overview of the new Mlab cusing R

  • Machine for LaserCUSING with a low level of investment
  • Compact machine
  • Benefits in order throughput time
  • High material density
  • Less reworking
  • Standardised production process
  • Constantly high quality
  • Less wastage
  • Fewer material costs
  • Improved efficiency
  • Increasing range of materials to currently include: gold, silver alloys, bronze, titanium, titanium alloys, cobalt-chromium alloys and stainless steel

Benefits in the choice of materials

The new Mlab cusing R offers universal material options: gold, silver alloys, bronze, titanium, titanium alloys, cobalt-chromium alloys and stainless steel, all can be currently processed generatively.

For dental technology, Dentaurum is the partner of Concept Laser. The Dentaurum Group, which leads the way in the field of stainless-steel-free alloys, produces exclusive powder materials to order for the LaserCUSING process. Two patented and clinically proven materials which were previously available as alloys in the form of cast cylinders and as milling blanks for conventional fabrication are now available to users exclusively in powder form: remanium® star CL and rematitan® CL.

The products which are produced using the laser-fusing process meet the requirements of the German Medical Devices Act (DIN EN ISO 9693 / DIN EN ISO 22674).

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