Sciaky, Inc.

United States

Sciakys turnkey metal additive manufacturing systems can do it all. Our Electron Beam Additive Manufacturing (EBAM) systems bring value throughout the entire product life cycle. Pre-Production: Create experimental metal prototypes faster than ever before and get a leg up on your competition.Production: Additively manufacture metal parts (in your own facility) with significantly reduced machining time, material costs, and lead time compared to traditional subtractive manufacturing methods.Post-Production: Repair or remanufacture damaged and obsolete metal parts on-site so you can extend various components service life.EBAM was launched in 2009 with the objective to save manufacturers significant time and money on the production of high-performance metallic structures. Today, EBAM is the worlds most cost-effective process for producing near-net shape parts made from virtually any metal, including high-value metals like titanium and tantalum.

Sciaky designs and manufactures medium vacuum chamber EB welding systems with state-of-the-art internal moving guns. These systems commonly utilize low voltage and high power, and are ideally suited for medium-sized parts.Motion system designs include ceiling mounted gantries and rear-wall mounted booms that, depending upon system configuration, manipulate the EB gun using X, Y, Z, and gun tilt.Standard designs are available, and custom engineered solutions are often created to meet customer requirements.Scalability of process to weld thin foils to thick sections (greater than 2.5" depth-of penetration).CNC control systems coordinate all EB process parameters.High depth-to-width ratio weld profiles provide low distortion and excellent mechanical properties.The high vacuum environment provides an excellent inert environment for welding many reactive metals and alloys with pumping technologies up to 200, 000 ls.High precision and repeatability.Sciaky offers many standard CNC-controlled part manipulators, designed in several load capacities, including rotary tables, rotary headstock tailstocks, and rotary tilt positioners.

Sciaky's AcuWeld 1000 Advanced Arc Welding System is known throughout the industry for its flexibility, ease-of-use and superb quality--it supports Gas Tungsten Arc Welding (GTAWTIG) and Plasma Arc Welding (PAW) applications. The AcuWeld 1000 integrates the welding process with all machine movements, providing complete control through a single W2020 computer system. Menu-driven programming and a portable operator's pendant make the system very user friendly.

Parts that are additively manufactured without a control system can have many quality issues. Since part quality for metal is affected by parameter settings in the deposition process, uncontrolled settings can lead to variability in layer geometry, mechanical properties, microstructure, and possibly chemistry. Traditionally, deposition settings and adjustment of parameters were analyzed by an operator and manually corrected, resulting in variable part quality. This limitation is possibly the single largest barrier to the adoption of Additive Manufacturing [AM]. The IRISS real-time closed-loop control is integrated with Sciaky EBAM 3D-printing systemsDigital parameter control and adjustments are made in response to real-time measured data, without process disruptionRecords every second of deposition, so the entire build can be reviewed, verifying consistency and keeping a record for later reviewPrevents surprises by dynamically adjusting parameters to maintain part integrityBetter insures net shape fabrication and reduces post processing time and costs such as machining and inspection

Sciaky specializes in large vacuum chamber electron beam welding systems with state-of-the-art internal moving guns. These machines commonly utilize low voltage and high power, and are ideally suited for large-scale parts. Advantages of large-scale EB welding machines include: Motion system designs include ceiling mounted gantries and rear-wall mounted booms that, depending upon system configuration, manipulate the EB gun using X, Y, Z, and gun tilt.Standard designs are available, and custom engineered solutions are often created to meet customer requirements.CNC control systems coordinate all EB process parameters.High depth-to-width ratio weld profiles provide low distortion and excellent mechanical properties.The high vacuum environment provides an excellent inert environment for welding many reactive metals and alloys with pumping technologies up to 200, 000 ls.High precision and repeatability.Sciaky offers many standard CNC-controlled part manipulators, designed in several load capacities, including rotary tables, rotary headstock tailstocks, and rotary tilt positioners.Scalability of process to weld thin foils to thick sections (greater than 2.5" depth-of penetration).

Sciaky, through its partnership with EVOBEAM GmbH of Germany, now sells and supports advanced Rapid Cycle EB welding systems manufactured by EVOBEAM. These systems utilize low voltage and low power, and are ideally suited for rapid production of small-scale parts. Customization of individual customer requirements is achieved by applying engineering principles focused on custom fit working envelopes, kinematic flexibility, mechanical precision, short pump down times, dry (hydrocarbon free) vacuum, proven EB gun and power supplies, and state-of-the-art CNC controls. Taking customer part production requirements into account, EVOBEAM Rapid Cycle EB welding systems can be configured for manual single part flow or adapted with automated high-volume part handling equipment.

Sciaky's external electron beam welding gun is the most advanced external EB welding gun on the market today. The triode-designed 60kV external gun is manually adjustable within +- 3 inches in the X direction, significantly improving narrow beam geometry. The gun's cantilever configuration makes filament replacement quick and easy. A direct-mounted turbomolecular pump, with an isolation valve, maintains the gun's vacuum at better than 1 x 10-4 Torr for superior performance. A high resolution CCD camera and monitor offer controls for optical focus, zoom, shutter, iris and an adjustable cross-hair for beam targeting. The gun column is constructed of stainless steel and utilizes internal coils for beam focusing and deflection.