Hybrid Manufactured Inconel Component
Imperial Machine and Tool Co. has been in the business of manufacturing for 73 years. A family-run firm, the New Jersey-based machine shop started out in the Forties when founder Michael Joest seized the manufacturing opportunities afforded by WWII. In the decades that followed, the company has continued to evolve with the times and the advancements that came with it. In the 70s that meant becoming early adopters of computer controlled machining centres. Now, the company has turned its hand to metal additive manufacturing (AM).
The latter began to materialise a little over four years ago when the team sat down to discuss the company’s future, and the possibility of purchasing another 5-axis machining centre. Around that time, General Electric had just completed its acquisition of Morris Technologies, a significant mark of industry approval that inspired the large machining facility, which had already been using polymer 3D printing for prototyping for some time, to take a closer look at metal AM.
“We didn't know for sure what metal AM was going to bring, but we knew that it was important to get involved early,” Christian Joest, Vice President of Sales and Business Development and son of company President, Christian M. Joest, told TCT. “Being a family business, we approached the decision thinking about the next generation rather than next year’s profits. We recognised metal AM was going to play a central role in the future of advanced manufacturing.”
Thread Milling Additively Manufactured Component
After visiting a number of key metal AM companies, the decision to purchase an SLM Solutions 280 HL powder bed fusion system was made. Unsure where the potential market might be, the team spent the first five months learning the machine, getting to grips with its capabilities and teaching its experienced machining engineers how to transpose their years of knowledge to production with metal AM.
Four years and two metal AM machines later, Imperial is supplying complex and lightweight end-use additive parts to some of the most regulated industries in the world, including oil and gas, aerospace and defence. But it’s not just additive alone that’s giving Imperial the advantage when it comes to these challenging application areas. Christian says it’s the combination of AM with Imperial’s traditional machining expertise that’s provided a “significant advantage”, particularly in the last 12 months as the market has matured.
“Our team delivers intricate end-use AM components by employing what we call a ‘Hybrid Manufacturing’ approach. After fabricating a complex design on our metal powder bed systems, we’ll finish the part using precision machining centres. This is absolutely vital in order to achieve the critical tolerances and features our customers need. Many applications require special SAE ports, flatness callouts on critical mating surfaces, or surface finishes that AM systems can’t achieve alone. It’s this holistic approach to AM that has really benefitted us on a competitive level. Rarely do you find metal AM capability combined with other advanced manufacturing services.”
Two SLM systems at Imperial's machine shop
As the industry grows, so does the need for better training and education. Imperial has been working to overcome this challenge by developing an internal training program and helping customers understand how AM fits based on real-world experience.
“I would say that educating people is probably the most difficult part of additive manufacturing. Most of the time, we have to start customer conversations on the ground floor, and make it very clear when and why additive makes sense. It really has to add something unique to the part. There’s a misconception that additive is a solution to everything, and that’s not the case. Education can be a slow process, but once the ‘light bulb turns on’ and a customer really grasps the value of AM, we’re able to develop some truly incredible designs.”
Imperial was invited to speak at RAPID + TCT this year to share insights learned on their journey into metal AM. As the industry rapidly expands, this insight is particularly relevant.
“It's extremely important to get the message out that using additive and subtractive manufacturing technologies together – not just additive on its own – is what’s allowing truly innovative breakthroughs. Additive is not going to replace CNC machining; it’s going to complement it.”
