64 | Metalspray Engineering T T Russell Fredric 3D printer just the latest innovation Designed and manufactured in the United States of America, the Markforged FX10 is the first industrial 3D filament printer in the world capable of printing both metal and composite parts, “It puts us right at the top of the table in Otago for that technology. You’ve got the ability to print a part that can’t feasibly be machined.” ENGINEERING The purchase of a world-first 3D printer that can create metal parts represents a quantum leap for Dunedin engineering business Metalspray Engineering. Managing director Thomas Mckay is excited about the new machine, which is a large investment, and for the possibilities and key advantages it offers. Designed and manufactured in the United States of America, the Markforged FX10 is the first industrial 3D filament printer in the world capable of printing both metal and composite parts, opening a whole new world of applications through a convenient and highly cost-effective process. The FX10 can print a wide variety of plastics and composites, including food-grade nylon, carbon fibre, Onyx – a nylon mixed with chopped carbon fibre that is a high strength thermoplastic, and Kevlar. Metal available is 17-4PH stainless steel, 316L stainless steel, copper, tool steels H13 and D2, and Iconel 625, a nickel-based superalloy. “It’s our next level up in machinery,” Thomas says. “It puts us right at the top of the table in Otago for that technology. You’ve got the ability to print a part that can’t feasibly be machined.” Applications include producing prototypes or parts that what would otherwise have long lead times, or would be very expensive to source from OEM manufacturers. Metalcraft Engineering is happy to manufacture one-off parts for private customers and hobbyists, as well as for commercial clients. The FX10 can manufacture items of very small dimensions and up to 300mm square by 375mm in height, with a key feature being the high quality of the finish compared to lower- cost consumer/prosumer 3D printers. “A bonus is the quality, it’s incredible. With this you can hardly see any print lines,” says Thomas. The purchase of this printer reflects Metalspray Engineering’s ongoing commitment to technology since it was established in 1958, when founder John Shanks imported the first metal-spraying machine into New Zealand, creating a new niche in the local engineering industry. Thermal arc metal spraying is a thermal spray process that uses an electric arc to melt metallic wires. The molten metal is then atomised with compressed air and propelled on to a metal component to form a metal coating, enabling damaged or worn parts to be repaired at a fraction of their replacement cost. “We can repair shafts that are worth $10,000 for a few hundred dollars. For clients, it’s huge. I think we’re the only business in the South Island still doing it. It’s quite a niche market.” Metals that can be sprayed are chrome, copper, bronze, zinc, aluminium, stainless steel and steel. Once the part has been sprayed, it is then machined to its required dimensions. Other specialised machines in Metalspray Engineering’s workshop are an EMD wire cutter, along with EMD spark erode, surface grinders, cylindrical grinders, and large 3- and 4-axis CNC milling machines Alongside all this technology, Metalspray Engineering is a full-service business with an extremely well-equipped workshop for general and maintenance engineering, machining, milling, and tool making, offering a 24/7 emergency callout service. Thomas and his business partner Simon Carter, a lawyer, bought the business last December. The company was previously owned by Simon’s parents Ian, also a lawyer, and his wife Mary Carter, with manager, Warren Thompson, having overseen its day-to-day operations for four decades. Thomas is a qualified fitter/machinist and previously worked for Metalspray Engineering for nine years before working for two other companies until the opportunity to purchase the business arose. He is enjoying being hands-on at the helm and having a supportive and talented team behind him, who pride themselves on the high standard of work Metalspray Engineering has long been renowned for.
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