Modern additive manufacturing of metal components at the Hardt site

As a leading developer and manufacturer of industrial magnet systems based in the Black Forest, we continuously invest in state-of-the-art production technologies and forward-looking processes. We have recently added a state-of-the-art metal 3D printer – the Metal X system from Markforged – to our in-house machinery. With this investment, we are further advancing additive manufacturing for metal components in southern Germany and offering our partners even faster, more flexible solutions in the fields of toolmaking and prototyping.

Unlike traditional metal laser sintering (DMLS), which requires extensive safety precautions due to the use of reactive, loose metal powders, the Markforged Metal X utilises the safe ADAM (Atomic Diffusion Additive Manufacturing) process. In this extrusion-based 3D printing process, the metal powder is bound within a plastic filament. This makes our in-house process not only extremely safe, but also significantly more agile and cost-effective.

Modern technology for the best results: Metal X specifications at BRUGGER

A sophisticated, three-stage process – from 3D printing the green part, through washing out the plastic binder, to the final sintering in a high-temperature furnace – guarantees us metal parts suitable for industrial use with excellent mechanical properties. Key technical specifications of our new printer at a glance:

• Optimal build volume for industrial applications: With a build volume of 300 x 220 x 180 mm (W x D x H), we can print everything from compact components for magnetic systems to robust assembly aids in precisely tailored sizes. It can also be used for initial printed prototypes or pilot production runs.

• Highest precision thanks to fine layer resolution: After sintering, the components achieve a fine layer thickness of between 50 and 125 micrometres, ensuring outstanding surface finish and dimensional accuracy.

• Versatile choice of materials (stainless steel, copper & tool steel): The printer enables the processing of heavy-duty industrial metals. These include the extremely robust and abrasion-resistant 17-4 PH stainless steel, pure copper for optimum thermal and electrical conductivity, and tool steel with longevity, D2.

• Lightweight construction thanks to closed-cell infill (honeycomb structure): A huge advantage for modern mechanical engineering: we can generate closed, cellular infill structures (honeycomb structures) within the components. In this way, BRUGGER produces sturdy prototypes that offer massive savings in weight and material without compromising on strength, whilst matching the weight of aluminium.

Conclusion: Tailor-made, fast and sourced directly from the region

With our recent acquisition of the Markforged Metal X, we at BRUGGER are underlining our commitment as an innovative solution partner and guarantor of ‘Made in Germany’ quality. As we carry out metal 3D printing directly at our site in the Black Forest, there is no need for long supply chains or external subcontracting. We can now produce bespoke end-use parts, specialised gripper jaws, devices and functional prototypes even faster, more cost-effectively and with greater flexibility in our own facilities. This benefits both our own development cycles for magnetic systems and our industrial customers throughout the region.