Metal 3D Printer

Create Your Future

“Create Your Future,” is a phrase we use a lot at Sodick. That’s why we’ve developed the next step in Metal 3D Printing: a single machine capable of producing a complex mold in one piece, unattended, in less time and with less material than a conventional machine tool. The Sodick OPM250L is not simply another Metal 3D Printer, it is the evolution of 3D printers. Previous 3D printers have been limited by an inability to produce a good surface finish - so we incorporated a Rigid Linear Motor driven mill. The 400W laser on other printers yielded components with reduced density - so our powerful 500W ytterbium laser achieves a 99.9% melting ratio. No existing CAM system could handle an integrated DMLS printer/mill - so we made our own. Create Your Future isn’t a mantra; it’s a challenge.

Unparalleled Finishing

Unlimited Complexity

Unlike first-generation 3D Printers, the Sodick OPM250L is capable of producing finished parts, thanks to its integrated high speed mill. Throughout the printing process, the workpiece is regularly machined to achieve the greatest finish possible, even on many hard to reach, internal structures. The OPM’s 45,000 RPM spindle achieves fine finishes far greater than those achieved on laser-only printers.

Metal 3D Printing is unlike any process seen before; creating solid components layer by layer, 3D printing is not limited to machining from the outside of a part to the inside. Instead, lasers melt shapes within a bed of powder, which solidify into fully dense, three-dimensional objects. The results speak for themselves: curved and hollow workpieces with complex internal structures are readily available to OPM users. The advent of Metal 3D Printing as a production process has opened the door for designs which would have been impossible with conventional tools. With the ability to create virtually any shape, Metal 3D Printing has cornered the market on the most advanced and complex part manufacturing.

Introducing: Sodick Metal 3D Printing

Recoating

Laser Sintering

High-Speed Milling

Rigid Linear Motor

Dedicated NC Unit & CAM System

Sodick Motion Control

Advanced Chamber Technology

Sodick’s rigid linear motors utilize rare-earth magnets mounted into the machine castings to create a direct-drive force along each axis. By using a digitally controlled magnetic drive, rigid linear motors eliminate the mechanical friction, wear, vibration, and backlash of traditional ballscrew drives, and require no drive alignment from the user. Together with absolute glass scales, the rigid linear motor achieves a level of precision not possible with analog technology.

The OPM250L introduces the first LN2RP NC Unit, developed expressly for fully integrated laser sintering and finishing. Likewise, the OPM250L offers the Z-Asso CAM system, also designed specifically for integrated additive and subtractive manufacturing. Z-Asso is fully compatible with a variety of CAD data, including IGES, STEP, Parasolid, and STL. This dedicated system not only produces machining data, but also optimizes the cutting of high load areas and offers full simulation capabilities.

Produced in Silicon Valley, CA, Sodick’s motion controller technology optimizes performance in real time, making over 500 adjustments per second. Equipped with the latest motion control chip, the M-4 Link, Sodick’s OPM250L utilizes advanced fiber optic cabling and a 2.26 GHz Dual Core Processor, making the OPM250L one of the smartest machine tools available.

Few realize that Sodick is an expert in vacuum chamber design, with over 10 years of production experience. First designed in 2003, Sodick’s vacuum chamber technology has been tested in the PIKA Finish Electron Beam Machine with great success. By maintaining a high concentration of inert gas, Sodick’s vacuum chamber achieves stable and accurate laser sintering.

Material powder is evenly distributed over the work space in preparation for laser sintering.

A 500W laser binds the material, achieving an unprecedented 99.9% melting ratio. Multiple passes produce each layer of the workpiece.

After every 10 passes by the laser, milling is performed to improve accuracy and finish, inside and out.

Integrated Additive/Subtractive ManufacturingFor the first time, Sodick’s OPM250L makes it possible to 3D print a metal workpiece while simultaneously milling the print in the same workspace. Not only does this integration improve part accuracy and eliminate post-processing, but by milling throughout the printing process, hard-to-reach and interior surfaces can now be machined without additional effort. The automated OPM250L truly makes Metal 3D Printing a full-fledged production process, achieving a finish which is impossible with traditional 3D Printers. Reducing the number of components necessary for complex molds and making conformal cooling a reality, this machine achieves significant improvements across the board - not only in precision but also in production speed and cost.

Compared to print-only systems, which only permit post-processing of external surfaces, OPM250L’s superior integration allows for greater complexity and precision. Moreover, because OPM250L streamlines all modules into a single unified system, it is the ideal candidate for remote monitoring and operation.

One-Process Machining: 3D Metal Printer & High-Speed Milling Core Technologies

S i m u l a t e d r e s i n temperature diagram (3D cooling channels)

[Cavity]

[Core]

[Cavity]

[Core]

Measured deformation values [Conventional mold]

0 0.5 （mm）

� Cooling time: 10 s� Cooling time: 5 s

①

②

③

[OPM mold]

0 0.5 （mm）

①

②

③

①

②

③

Software Model of 3D Cooling Channels

Plastic injection molding performance is heavily influenced by the construction of the mold used. Temperature, in particular, is a significant factor, as variations in temperature across a mold can cause deformation. In traditional mold manufacturing, cooling channels can only be designed along two dimensions, making it difficult to evenly cool complex molds. This is not true of molds made with OPM250L, which can produce cooling channels for nearly any shape.

OPM250L is capable of producing 3D cooling channels which are freely positioned inside the mold. By improving the cooling performance of highly complex molds, these conformal cooling channels greatly improve cycle times while optimizing mold shrinkage. These cooling channels may easily be simulated using software such as Moldex 3D (Core Tech System Co., Ltd.) and are capable of reducing cycle times by over 20%.

OPM 3D CoolingConventional 2D Cooling

Conventional vs. 3D Cooling

Reduced DeformationBecause conventional mold cooling methods are inefficient, deformation has traditionally been estimated during the mold design process. However, by optimizing 3D cooling channels, it is possible to design molds with zero deformation while still cutting mold cooling time in half. The significant improvements in productivity offered by OPM250L molds add up to real dollars for plastic injection molders. Better still, OPM250L achieves a melting ratio of 99.9%, ensuring that conformally cooled molds are dense enough and durable enough to withstand the extreme pressures associated with molding.

Component Produced By

145.000

130.000

106.000

121.000

OPM250L Mold

Conventional Mold

Molding cycle 22 sec. 27 sec. 32 sec. Cooling time 5 sec. 10 sec. 15 sec. Conventional piping 0.60mm 0.35mm 0.20mm 3D cooling piping 0.25mm 0.15mm 0.15mm

3D Conformal Cooling Channels Cycle Time Reductions & Cooling Efficiency

Factory site Design Control

Process management by a scheduler that is compatible

with Sodick machines

Create NC program -> Transfer to machine

Consolidate management of machine operation, analyze and use the acquired data

Error

Conventional mold production

OPM mold production

Lead time withOPM250L machines: 24

days

Design

Design AssemblyMachining

AssemblyMachining

[Machining] 443.29 hours [Unmanned machining] 668.21 hours

[Unmanned machining] 493 hours

Lead time: 54 days

OPM250L OPM250L

52 parts 52 parts

3 parts

Cavity1Core2

3 parts

Cavity1Core2

Security MeasuresSodick NC units apply the following security measures to the network connections.

• System protection with the FBWF (File-Based Write Filter) function

• Data communication between power supply and external PC using FTP;

Mold manufacturing has long been a labor-intensive endeavor, requiring numerous complex processes on a variety of machine tools. By integrating both laser sintering and high speed milling into a single process, OPM250L eliminates many of these subsequent processes. With the capability to manufacture finished molds with one-piece construction, the OPM dramatically improves the production process.

By simplifying production, the OPM250L makes it easy to operate the OPM from a remote location. Provided with the necessary mold data, our additive machine is capable of unmanned machining from start to finish, reducing lead times, labor, and overall costs. The OPM system’s flexibility makes it possible to produce uniform, high-quality molds from anywhere.

Unmanned, Automated, and Remote Operation

Fully Secure Networking

Remote operation need not be risky operation. To guarantee the security of your data, Sodick’s OPM comes fully equipped with advanced security measures. All communications between your machine and your PC are protected by a secure File-Transfer Protocol (FTP), and only Sodick-certified USB connections are permitted.

With execution of non-CNC files locked, you can rest assured that the Sodick OPM250L keeps your network connections, and your data, securely in your hands. The manufacture of complex molds once required a large scale production facility. To produce the molds above, it

once took 3 Machining Centers, 6 Wire EDMs, 6 Sinker EDMs, 4 Grinding Machines, and a Mill. Production of this scale requires a considerable investment not only of machining time, but also design and assembly. Today, the same molds are produced in less than half the time with only 2 OPM250L machines, and the entire machining process is unattended. The result is reduced costs, increased productivity, and greater overall profitability.

Significant Reductions in Lead Time

Eliminate Multi-Part Mold DesignsPart

namePart

numberAmount

Front Insert 10100 2

Front Insert 10200 1

Front Insert 10300 1

Front Insert 10400 2

Front Insert 10500 1

Front Insert 10600 1

Front Insert 10700 1

Front Insert 10800 1

Front Insert 10900 1

Front Insert 11000 2

Front Insert 11100 2

Front Insert 11200 1

Front Insert 11300 1

Front Insert 11400 2

Front Insert 11500 2

Rear Insert 50100 1

Total 21

Cavity (FRONT) 21 parts Core (REAR) 31 partsPart

namePart

numberAmount

Rear Insert 50100 1

Rear Insert 50200 2

Rear Insert 50300 2

Rear Insert 50400 2

Rear Insert 50500 1

Rear Insert 50600 1

Rear Insert 50700 2

Rear Insert 50800 2

Rear Insert 50900 1

Rear Insert 51000 2

Rear Insert 51100 2

Rear Insert 51200 1

Rear Insert 51300 1

Rear Insert 51400 1

Rear Insert 51500 2

Rear Insert 51600 2

Rear Insert 51700 2

Rear Insert 51800 2

Rear Insert 52000 1

Rear Insert 52100 1

Total 31

The limitations of conventional manufacturing processes have, until now, made it impossible to produce truly complex molds in one piece. Instead, moldmakers have had to produce complicated mold designs, sometimes consisting of dozens of pieces.

Through additive manufacturing, it is now possible to optimize mold designs to reduce the number of pieces required. A mold which once required 52 pieces in total can today be produced in as little as 3 parts. This greatly reduced the number of processes required, ultimately saving both time and labor.

Conventional Process

Reduced

55%

Remote Design & Production Process Improvements & Cost Savings

Example

CAD Model Import

Create Laser Data

Optimize Cutting Data

Simulation

High-Speed Spindle, CCD Camera Automatic Tool Changer (ATC) Automatic Tool Length Measurement

500W Fiber Laser Exhaust Port

Unused Material Receptacle Nitrogen Gas Generator Dual-Tank Material Feeder

Sodick’s 45,000 RPM Spindle is paired with a laser positional correction system

16 Position ATC Capacity Automatically measure distance from spindle reference to tool tip

Cut costs by recovering unused material and recycling it back into the feeder

Supply nitrogen gas to the machining area

Automatically supply material to the recoater head using high-capacity tanks

Sodick Z-Asso is a dedicated CAM system designed specifically for integrated metal printing and milling on the OPM250L. This system offers the flexibility to handle various CAD data inputs, including IGES, STEP, Parasolid, and STL. Using this data, Z-Asso uses unique algorithms to quickly generate laser and cutting data with a high degree of accuracy.

Using a 3D offset, various laser data can be generated, including a two-layer structure consisting of melt parts and core parts. Fully compatible with STL files, Z-Asso also enables mold manufacturing from scanned data.

With fast and sophisticated editing capabilities, it is easy to optimize cutting data to reduce both cutting time and cutting loads. High load areas such as grooves and corners are automatically detected and feed rates automatically adjusted.

Cutting simulations can be used to verify the process data after laser and machining paths have been generated. These simulations include a time function to calculate remaining cutting time, improving project management.

Z-Asso Dedicated CAM System Features & Accessories

Mold manufacturing (sintering) time: 25 hoursCutting time: 33 hoursTotal time: 59 hoursMold size: 60 mm x 40 mm x 40 mmMaterial: Maraging SteelTools: 1 and 2 mm dia. ball end mills

Mold manufacturing (sintering) time: 19 hoursCutting time: 36 hoursTotal time: 55 hoursMold size: 120 mm x 70 mm x 73 mm (Including plate size)Material: Maraging SteelTools: 1 and 2 mm dia. ball end mills, 1 mm dia. flat end mill

Mold manufacturing (sintering) time: 25 hoursCutting time: 44 hoursTotal time: 69 hoursMold size: 92.1 mm x 36.3 mm x 33 mmMaterial: Maraging SteelTools: 1 and 2 mm dia. ball end mills

Mold manufacturing (sintering) time: 39 hoursCutting time: 71 hoursTotal time: 110 hoursMold size: 79.6 mm x 39.8 mm x 61 mm Material: Maraging SteelTools: 1 and 2 mm dia. ball end mills, 1 and 4 mm dia. flat end mill

To improve cooling around the central ribs, conformal cooling channels have been placed in a pattern surrounding this area. The OPM250L has actually machined the interior of these cooling channels, enhancing surface roughness and allowing a greater volume of cooling medium to flow through the 1.2 mm diameter channels. All machining can be performed by a single process on OPM250L, including the perimeter rib arrangements.

A spiral cooling channel has been positioned within the protrusion. This region would be difficult to cool using conventional techniques, and the use of conformal cooling channels has greatly improved its efficiency. An additional peripheral cooling channel is also used to provide uniform cooling and reductions in deformation.

The OPM250L makes it possible to machine spiral cooling channels inside of a curved shape - impossible with traditional machine tools. This high-precision processing of deep ribs and internal spiral structures can be achieved on just one machine.

Cooling channels can be designed at the center of a cylinder to achieve effective cooling along surrounding ribs. Moreover, these ribs can only be finished by the OPM250L, which mills throughout the production process.

EV Connector

Switch Box

Duct Shape Core

Cylindrical Fin Core

OPM250L Samples OPM250L Samples

Air In

600

1870

20851452230 1798

100

781 617300

4028

1531

1558

930.

5

2288

2055

233

600

1870

2085145

2230 1798

100781 617300

4028

1531

1558

930.5

2288

2055

233

Nitrogen Gas Generator

5330

180022306002085

790830

1230655

145

600300

300 783 617

680

1459

315430

0.7MPa~H=1285mm

430

1070

100

Cooler Assy

Fume CollectorInput Power Supply3-Phase AC200/220V

H=1020mm

1756

3001870

600

Leveling Block(Bed)(5 Posi)

Leveling Block(Base)(4 Posi)

2770

Power Supply

Machine

700

unit：mmMetal 3D Printer

OPM250L

Max. Object Size (WxDxH):

260 mm | 10.24”

Y-Axis Travel:

U-Axis Travel:

Spindle Z-Axis Travel:

Machining Tank Internal Dimensions (WxD):

Max. Powder Feed Amount:

Nitrogen Supply Capacity:

Machine Tool Dimensions (Excluding Peripheral Equipment):

Machine Tool Weight (Excluding Peripheral Equipment):

Laser Type:

Laser Wavelength:

Max. Laser Output:

Laser Scanning:

Max. Spindle Rotation Speed:

Max. Spindle Torque:

ATC Tool Holders:

Tool Holder System:

Machine Tool

Laser

Spindle & ATC

250 mm x 250 mm x 250 mm | 9.84” x 9.84” x 9.84”

260 mm | 10.24”

260 mm | 10.24”

X-Axis Travel:

100 mm | 3.94”

290 mm x 290 mm | 11.42” x 11.42”

90 kg | 198.4 lbs

32NL/min

1,870 x 2,230 x 2,055 mm | 73.62” x 87.79” x 80.90”

4,500 kg | 9,920 lbs

Yb Fiber Laser

1,070 nm

500 W

Galvano Method

45,000 RPM

0.8 Nm

16

Dual-Contact Shrink-Fit Holder HSK-E25

LN2RP NC Unit

Control Axes:

Simultaneous Control Axes:

Minimum Input Command:

Minimum Drive Unit:

X, Y, Z, U, spindle, +B

Max. 4 Axes

0.1 um

0.031 um

Options

demagnetizer Tesla meter

shrink �tting device industrial vacuum

spindle cleaner tool cutting machine (SCM-3)

axial probe heat robo

*Only Sodick-designed material powders should be used in the OPM250L*Always use Sodick base plates compatible with your chosen metal powder*When using metal powders, ensure that the work environment conforms to all applicable safety and health regulations.

OPM250L Specifications OPM250L Layout

*The export of Sodick’s products and related technologies (including software applications) is regulated under Japan’s Foreign Exchange and Foreign Trade Control Law. In addition, because some of these products may be subject to re-export controls under the Export Administration Regulations (EAR) of the United States, please contact Sodick before o�ering or exporting these products overseas.*This catalogue contains photographic images generated from 3DCG*Due to ongoing research, speci�cations are subject to change without prior notice*The contents of this catalog are current as of May, 2016

OPM250L Metal 3D Printer