23 June 2021
SmartTeeth: Super-hard tooth formation on linear edge saw blades using Selective Laser Melting process
For high performance cutting blades, the most common high-performance tooth tip material is tungsten carbide. However, traditionally a 'tipped' blade uses less than 1% of the starting quantity of high value wear material, the rest is machined off during the manufacturing process or left on the substrate and discarded when the sharp edges are worn.
Over the past 2 years, C4 Carbides has teamed up with TWI Ltd to develop innovative saw blades using Powder Bed Fusion-Laser Beam (PBF-LB), a metal Additive Manufacturing (AM) technology, to fuse super-abrasive powder to form tooling grade hard materials into net shape cutting teeth. PBF-LB technology is well known for its capability to produce fine features, with sub 50µm layer height, to form accurate net shape objects.
The SmartTeeth project is leveraging the design freedom of the technology to create a new generation of saw blades with complex cutting tip designs with unparalleled performance. It will also deliver environmental benefits including material saving of 70-80% and energy and production savings of over 50% when compared to conventional carbide saw blade manufacturing.
This webinar will provide updates on the latest development in the project, along with a demonstration of saw blade sample production using PBF-LB and their cutting performance.
The SmartTeeth project is funded under InnovateUK Project Number 105745.
Senior Technical Project Leader
Amanda has an academic background in Materials Engineering and is currently employed by TWI Ltd as a Senior Technical Project Leader in the Laser Additive Manufacturing section. Amanda’s current role involves research and development of Additive Manufacturing technologies, predominately Powder Bed Fusion – Laser Beam (PBF-LB). Amanda has experience in developing, managing and delivering a range of technical projects and has an interest in advancing and developing certification and standards for additively manufactured components.
Dr Choon Yen Kong
Additive Manufacturing Project Manager
C4 Carbides Ltd
Choon has over 12 years hands-on experience in DED-LB and other metal additive manufacturing (AM) and laser processing technologies. He joined C4 Carbides in 2018, focussing on the development of hard-facing technologies using AM. Prior to joining C4, Choon worked as Principal Project Leader at TWI, during which he was involved with and completed many high profile AM and laser processing projects, including several Innovate UK and EC funded projects. He completed his PhD in Advanced Manufacturing in 2005 from Loughborough University, investigating Ultrasonic Additive Manufacturing (UAM) technology for metal matrix composite production.
Section Manager and Technology Consultant, Laser Additive Manufacturing
Dr Carl Hauser joined TWI in June 2010 and is section manager and technology consultant in the Laser Additive Manufacturing (LAM) section. Carl has been involved in additive manufacturing for more than 25 years. Carl steers technical strategy for both PBF-LB and DED-L and still conducts some experimental research in large scale AM. This includes the development of certification procedures and CAM software tools for DED-L processing.
Carl has published over 30 scientific conference and journal papers, has given many keynote presentations on Additive Manufacturing, and is an expert reviewer for several international additive manufacturing journals. Carl also sits on the advisory committee for the International SFF Symposium, held annually in Austin, Texas. Carl is a chartered engineer and has attained Fellow status with The Welding Institute.
Metal Additive Manufacturing Engineer
C4 Carbides Ltd
Pavels is a materials scientist with over seven years hands-on experience in mechanical engineering.
He has been investigating formation of super-hard metal-ceramic and ceramic-ceramic materials using localised heating and exothermic reactions since 2017, through his C4 sponsored PhD study at the University of Hertfordshire.
Since joining C4 in 2018, Pavels has been actively developing what is now known as Reactive-DED technology, which uses environmentally friendly and energy efficient in-situ carbide formation to form mechanically advanced, functional and impact resistant tungsten carbide deposits on dissimilar substrates using the DED-LB process.