Additive manufacturing systems from FOOKE

At FOOKE GmbH, specialists in portal milling machines and friction stir welding systems, we are now paving the way for the future by introducing a newly developed machine tool for the production of large-format additive components. Benefitting from many years of experience in mechanical engineering, we are combining our expertise in Friction Stir Welding (FSW) with additive manufacturing. The result is a machine that is capable of manufacturing large-volume components from >300mm side length using the ‘Additive Friction Stir Deposition’ process. 

The AFSD process is based on friction stir welding, which means that the AM50 fits perfectly into FOOKE's machine portfolio. The restrictions in terms of dimensions, starting material and deposition rate are negligible, as the process, unlike many common metal-based AM processes, is actually of a solid-phase nature and therefore does not involve bringing the material into the melt for processing. As a result, AFSD benefits from low residual stresses and significantly lower susceptibility to porosity and cracking.

No melting – increased rigidity
This printing technology does not involve any melting, which keeps the thermal stresses in the component under control. In addition, a higher level of mechanical material characteristics is achieved compared to conventional build-up welding processes.

High material diversity
This technology can be applied to a wide range of common metals, including aluminium, titanium, stainless steel and others.

Sustainable, eco-friendly and efficient in terms of resources
With additive manufacturing, the desired components are fabricated close to the final contour, minimising the actual amount of material used. Subsequent post-processing of the components, e.g. by milling, is extremely efficient, as the printing close to the final contour requires low machining rates. The machining time can also be significantly reduced.

Customisable
Customised solutions and individual components are easy to implement using the AFSD process.

Repair
The process is also ideally suited for repair work (e.g. moulds). Compared to the acquisition of new moulds, it reduces maintenance times.

Flexibility of application
With additive manufacturing, there are no limits to the design - even functions that cannot be realised with conventional manufacturing processes can be integrated. Moreover, complete assemblies can be constructed in a single process, e.g. cooling channels or hydraulic lines.

Short production times and flexibility
Complex components can be manufactured directly and no longer require time-consuming procurement times. In addition, customised modifications, e.g. in prototype construction or pre-series, can be implemented quickly and easily.

High deposition rate of up to 14 kg/hour.
due to patented application process.

Material mix
The process enables mixed joints of different materials (e.g. copper and aluminium).

Reduction of milling rates
By producing close contour components, the need for post-processing can be significantly reduced.

Flexibility in the material supply chain
High availability of the printing material.

• 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.