Additive Manufacturing 3D printing

FOOKE GmbH is expanding its product portfolio with an innovative system for Additive Manufacturing 3D Printing, tailored for advanced industrial metal processing. Drawing on decades of expertise in mechanical engineering, high-precision gantry milling machines, and friction stir welding systems, FOOKE now introduces a cutting-edge solution for large-scale metal 3D printing.

The newly developed Additive Manufacturing system AM50 is engineered specifically for the production of large-volume metal components. It combines proven mechanical engineering excellence with state-of-the-art 3D printing technology, offering key advantages such as significantly reduced residual stresses, minimal porosity and cracking, outstanding process stability, and compatibility with a wide range of metal alloys.

The AM50 enables precise and reliable manufacturing of metal parts with edge lengths starting from 300 mm – making it ideal for demanding industrial sectors such as aerospace, mechanical engineering, and the automotive industry.

High-Performance 3D Metal Printing for Industrial Applications

The AM50 Additive Manufacturing 3D Printing system integrates seamlessly into existing production environments and provides companies with a powerful solution for cost-effective and flexible manufacturing of complex metal parts. Thanks to high deposition rates, minimal geometric limitations, and robust process control, it is ideally suited for serial production as well as rapid prototyping.

By combining FOOKE’s renowned quality with the vast potential of Additive Manufacturing and metal 3D printing, the AM50 represents a future-ready investment in advanced manufacturing technologies.

Additive Friction Stir Deposition (AFSD) – A Solid-State Approach to Additive Manufacturing

This system is based on Additive Friction Stir Deposition (AFSD) – an advanced solid-state additive manufacturing process in which metallic materials are plastically deformed and deposited layer by layer. Unlike traditional fusion-based 3D printing, AFSD does not involve melting, allowing for more stable, low-distortion production with superior material properties.

NO MELTING – ENHANCED MECHANICAL PERFORMANCE
Unlike traditional 3D printing or welding-based additive methods, Additive Friction Stir Deposition (AFSD) involves no melting of the base material. This solid-state process drastically reduces thermal stresses during production and enables the creation of components with superior mechanical strength and structural integrity compared to conventional build-up welding processes.

HIGH MATERIAL VERSATILITY
AFSD supports a broad range of metals, including aluminium, titanium, stainless steel, and other commonly used industrial alloys. This flexibility makes it ideal for multi-material strategies and complex application environments.

SUSTAINABLE, RESOURCE-EFFICIENT MANUFACTURING
Additive Friction Stir Deposition enables near-net-shape production, meaning components are printed close to their final geometry. This significantly reduces raw material waste and minimizes the need for extensive post-processing. Final machining steps, such as milling, require less time and effort, which translates into lower energy consumption and shorter production cycles.

CUSTOMISABLE SOLUTIONS FOR INDUSTRY
The AFSD process allows for the easy realisation of customised components and tailored solutions, adapting perfectly to the specific requirements of aerospace, automotive, and mechanical engineering applications.

IDEAL FOR REPAIR AND REFURBISHMENT
AFSD is also well-suited for component repair, such as mould refurbishment. Compared to replacing parts entirely, this approach reduces downtime and maintenance costs, extending the lifecycle of high-value industrial tools and components.

DESIGN FREEDOM BEYOND CONVENTIONAL LIMITS
With Additive Manufacturing 3D Printing, especially using Additive Friction Stir Deposition (AFSD), design limitations are virtually eliminated. Even complex internal functions—such as integrated cooling channels, hydraulic lines, or lattice structures—can be directly manufactured in a single process step. Complete assemblies can be produced without additional joining or assembly operations.

SHORTER PRODUCTION TIMES & MAXIMUM FLEXIBILITY
AFSD enables the direct production of complex parts, significantly reducing lead times. Customised adaptations, especially in prototype development or pre-series production, can be implemented quickly and efficiently—without lengthy procurement or tooling processes.

HIGH DEPOSITION RATES – UP TO 14 KG/HOUR
Thanks to FOOKE’s patented AFSD process, the system achieves deposition rates of up to 14 kg/h, making it ideal for large-scale industrial applications where productivity matters.

MULTI-MATERIAL CAPABILITY
The Additive Friction Stir Deposition process supports the creation of mixed-material joints, such as aluminium-copper combinations. This opens up new possibilities in lightweight design and thermal management.

MINIMISED POST-PROCESSING THROUGH NEAR-NET-SHAPE MANUFACTURING
AFSD enables the production of near-contour components, reducing milling and finishing requirements to a minimum. This results in lower tool wear, faster throughput, and reduced waste.

SUPPLY CHAIN RESILIENCE & MATERIAL FLEXIBILITY
The system uses readily available feedstock materials in square or rectangular form, enhancing supply chain stability and material sourcing flexibility.

• Automated Process Control: The FOOKE AM 50 offers real-time data monitoring, optimized process planning, and advanced fault detection, minimizing downtime and ensuring continuous production.
   
• User-Friendly Interface: The control software is intuitively designed, enabling quick onboarding even for new users, along with detailed configuration options for experienced operators.
   
• Safety Features: A closed system and extensive safety mechanisms ensure the protection of both operators and the machine.
   
• Machine Structure: The machine bed, with its attached X-guide and portal drive systems, is mounted and aligned on the designated foundation. The longitudinal beams, side panels (X-axis), portal (Y-axis), and ram (Z-axis) are each constructed as rigid steel welded structures.

• Drive Technology for Linear Axes: The X- and Y-axes are driven by a rack-and-pinion system, while the Z-axis is powered by a ball screw drive. The X-axis features two motors and drives, electronically synchronized to eliminate tooth flank play and gear backlash on each side.
   
• Guiding of Linear Axes: The linear axes are equipped with hardened, ground, preloaded, play-free roller guide elements.
   
• Axis Lubrication: The linear axes are fitted with an automatic central lubrication system. The round axes feature a low-maintenance long-term lubrication system.