Metal Powder Bed Fusion: FusiA Group’s Key Process for Producing Complex, High-Performance Parts

Metal powder bed fusion lies at the heart of FusiA Group’s expertise. This additive manufacturing technology enables the production of complex, lightweight, and high-performance metal parts, meeting the stringent requirements of the aerospace, space, and industrial sectors.

Two machines dedicated to performance

At FusiA Impression 3D Métal Inc., we operate two state-of-the-art powder bed fusion machines. This capacity allows us to adjust production parameters according to materials, geometries, and the specific needs of each client, while ensuring optimal flexibility and repeatability.

Process Explanation

The process consists of depositing successive layers of metal powder, locally fused using a high-power laser.Each layer is solidified according to the 3D model derived from the design, until the final part is formed.

The primary materials used at FusiA are aluminum, titanium, and stainless steel, selected for their excellent mechanical properties and high strength-to-weight ratio.

Advantages of Metal Additive Manufacturing

• Total geometric freedom: production of complex shapes impossible to achieve with traditional machining.

• Lightweighting and structural optimization: topological design and innovative internal structures.

• Material efficiency: a Buy-to-Fly ratio close to 1, minimizing material waste.

• Production agility: from prototype to pre-series, the process remains the same.

Supports are generated when necessary to ensure the stability and printing accuracy of parts.

Industrial Applications

FusiA implements powder bed fusion to:

• Produce critical aerospace and space components, including collaborative R&D projects.

• Manufacture custom tooling and components for industrial applications.

• Design lightweight and optimized parts using numerical simulation and topological optimization.

  
  

Quality Control and Traceability

Each part produced follows a rigorous quality process, including:

• Dimensional inspection and tolerance verification.

• Microstructural analysis to validate density and absence of defects.

• Aerospace and industrial qualification for critical components.

  
  

A Fully Controlled Process

Thanks to our expertise in metal additive manufacturing and our machining subsidiary, we perform all post-processing operations in-house.This full process control ensures responsiveness, consistency, and complete traceability for our clients.

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Article written by FusiA Groupe