Zenith Tecnica prints exclusively in Titanium Alloy (Ti6Al4V).
With such a capable material at our fingertips, we have been able to concentrate our efforts on becoming world leaders in the art of titanium alloy EBM manufacturing.
Thanks to our commitment to titanium, coupled with our humidity and temperature-controlled machine environment, we reduce any risk of cross-contamination and material impurities.
Yes and no.
While we do not design our customers components from scratch, our team is more than happy to collaborate with you to enhance your existing design to be more suitable for Electron Beam Melting manufacture, and enable you to leverage the unique benefits that EBM can achieve.
We offer new customers a free 1-hour session with our engineering team to evaluate your parts for EBM additive manufacturing and create a plan to get building.
Please see the full breakdown of our design services here
We are experts in the field of Titanium Additive Manufacturing, with some of the most extensive operating hours of EBM technology in the world. Our team has the highest levels of OEM training available and an embedded culture of continuous process improvement.
“Zenith Tecnica has put New Zealand on the global metal additive map. As an early adopter of Arcam EBM machines, the team has built a deep understanding of our technology that is second to none. It is no surprise therefore that this technical knowledge and engineering expertise is increasingly being sought out from customers around the world.”
– Oscar Angervall, GE Additive
Our team enjoys collaborating with customers and helping them design and manufacture innovative components. With our passion for EBM AM at the forefront of what we do, we are always looking to help those wanting to get into the world of additive. As such, we offer new customers a FREE 1-hour engineering consultation session to kick off your project(s).
Our standard lead time is 3 weeks for most job to batch manufacturing utilizing our ride-share option.
We provide options for ride-share and dedicated builds in order to give you the most cost-effective solution to fit your deadline. Lead time will depend on the build option used, the physical size and quantity of components, and any additional services required.
Electron Beam Melting (EBM) is a Powder Bed Fusion Additive Manufacturing (AM) process. Utilizing an incredibly powerful beam of electrons, this form of AM heats and selectively fuses metal powder together.
The process begins with an extremely thin layer of metal powder spread across a build plate and pre-heated. Once the desired heat is achieved, the beam accurately melts areas of powder at speeds of up to 8000m/s, which is approximately 28,800 kilometers per hour.
Once the layer has finished being melted, the plate descends a distance less than the average width of a human hair. From here a new spread of metal powder is applied and the next layer begins.
The design of the finished part is achieved through the creation of a 3D CAD Model that is digitally sliced into thousands of individual layers, acting as a blueprint for the beam to follow.
For more information on the process and how it works, click here.
Additive manufacturing (AM), also known as 3D printing, brings efficiency, sustainability and innovation to the forefront of your production line.
Unlocking design freedom and the production of complex parts, consolidated assemblies, and reduced mass without the sacrifices of time or quality.
Read more about how it is a sustainable manufacturing method here.
Whilst we live and breathe Titanium Additive Manufacturing, we also understand the diverse range of projects that we may come across. As such, it is a Zenith Tecnica policy to always be upfront and honest in assessing the suitability of your project for EBM AM.
Like any combination of manufacturing method and material, Titanium Electron Beam Melting has a time and a place that it thrives.
We have found that customers who make the most out of Ti EBM typically require one (or multiple) of the follow criteria:
Through utilizing the above, customers often find efficiencies they were not expecting:
Whilst we live and breathe Titanium EBM, we also understand the diverse range of projects that we may come across. As such, it is a Zenith Tecnica policy to always be upfront and honest in assessing the suitability of your project for EBM AM.
We have a comprehensive network of established partners that we work with regularly.
We can organize sub-contracting such as machining and/or HIP heat treatment as part of our service.
Our pricing and lead times are dependent on how much build volume your order requires. If you are able to fill an entire build volume, this will provide the most competitive pricing per unit, as well as more flexibility on launch times. We call this the Dedicated Build Option.
If you do not require such volume for your order, you will default to the Ride-Share Build Option. This option combines multiple customer orders together to ensure a competitive price is still achieved, and the pricing scales with the percentage of the build volume that you use.
Ride-share builds offer a standard 3 week lead time on all orders. If you require a faster lead time we can launch your order on a dedicated build. However, all relevant costs associated with the build will be split across the quantity of parts you’re ordering, so it is advisable that you fill the build when ordering a dedicated one.
For the fastest and most collaborative experience, we recommend using the following file types:
We can also work with the following common file types, but there may be some limitations in design capabilities:
*Mesh files should be in mm units and free of errors.
There are also many other file types we can work with that may not be listed above. Please submit your preferred file type if none of the above apply and our team will let you know if we require any further information.
Zenith Tecnica has validated the EBM process and Ti6Al4V to meet ASTM F2924.
ASTM F2924 | Ultimate Tensile Strength / UTS | Yield Strength (0.2% Offset) | Elongation | Reduction of Area / RoA |
|---|---|---|---|---|
ASTM E8 Min. | 895 MPa | 825 MPa | 10% | 15% |
Modulus of Elasticity: Approx. 120GPa
Density: 4.43gcm3
Important to Note: For highly or dynamically loaded thin walled geometries, our team advises HIP heat treatment and/or surface finishing and qualification with physical testing. This testing is best performed with representative samples or your component.
For additional mechanical property information please contact our team.
We offer material and product testing through 3rd party accredited labs.
We recognize the importance of providing an independent evaluation of our process to ensure confidence in the components we manufacture.
Every build that we run on our EBM machines includes test specimens for continuous material validation and traceability to demonstrate conformance to ASTM F2924.
You can order the following test certificate of any build, at any time:
We can also include specimens at your request for many other tests, including but not limited to:
Yes, we can 3D print threads and chase with a tap in-house. These threads are very cost-effective in light applications but are not validated for any classes of fit and should be validated for your application.
We recommend that threads are blanked and drill-tapped or machined for any critical applications.
A single component should fit within a ∅360x360mm [∅14.2″x14.2″] cylindrical volume.
If your part is within 20mm [0.8″] of these limits, please reach out to our engineering team for a definitive check.
Typical surface finishing will remove approximately 0.4mm of material. If surface finishing is specified on simple geometries our team can add this material allowance. However, if the surfaces are complex we will request that you allow for this material in the model you provide to us.
Yes but not all surfaces can be mirror polished, such as internal cavities and tight radii. This is highly dependent on geometry and in most cases, outside volume production, will be performed manually. Please contact our team to discuss at sales@zenithtecnica.com.
You can also see all of the available surface finishing services here.
Line of sight into cavities or hollow areas is preferred in order to be able to remove sintered powder from components after building. This is because powder does not simply pour out after the EBM process as it does with comparable PBF processes.
Failing line of sight, so long as we can access cavities with tools, we will be able to remove any support structures or powder. For this reason, EBM additive manufacturing cannot produce hollow structures with internal lattice without a method to remove sintered powder.
Our team will advise you after reviewing your files if there will be any difficulties with removing powder from your component.
Yes, EBM has a variety of capabilities that can enable different types of lattice structures to be built.
Porous structures are typically seen on medical devices, however are rarely used on EBM components for light-weighting due to the manufacturing considerations of cavities and hollow features. If you are considering light-weighting a design, our team is able to advise other strategies to achieve this as EBM is able to build thin walls with large cross section changes while leaving no residual stresses.
Structures below 0.7mm in thickness are not to be considered fully dense and it is recommended that validation and testing of components takes place before use.
Min. strut thickness: 0.3mm
We offer the service to apply lattice structures to your model. The component model must include separate solid bodies where lattice structures are applied or require generating. The lattice bodies should have at least 0.2mm overlap with solid regions.
No, we will take care of all the support structures needed.
Our Min. Wall thickness is 0.7mm
If you already have a design and 3D CAD model ready to go for additive manufacturing (AM), please see below for what we require to provide you with a quote and send us your inquiry!
If you are currently designing a part to be additively manufactured, or are looking to utilize AM for a future product, we can help you on your journey! We offer new customers a FREE 1-hour consultation with our engineering team to get your project(s) underway.
At a minimum we require these things to provide you with a quote:
CAD model of your component(s)
Quantities required
For our team to understand your application and provide tailored feedback, it is also best if you can provide the following:
Annual or repeat quantities required
Manufacturing drawing(s)
Including traceability and surface finish requirements*
Any features requiring post-machining should be indicated
* Contact our team for our technical guidelines or Design for EBM Manufacturing services to help specify these requirements.
A description of the next higher assembly, if applicable
Deadlines for urgent projects
Inspection requirements*
End-use declaration* (template can be provided)
Any classifications required for shipping and Export Compliance such as ECCN and HS code*
*If your inquiry is for a medical device or aerospace application, we require these details listed above.
We aim to get quotes back to you as soon as possible, however there are considerations that may lengthen the process.
Number of models | Quotes and estimates for printed components | Quotes including post-processing with subcontractors |
Repeat order* | 1-2 Business Days | 2 Business Days |
≤ 10 | 1-3 Business Days | 3-7 Business Days |
> 10 | We will respond with a time to quote after reviewing specifications. Please let us know your required timeline and we will do our best to accommodate. | |
*Within 12 Months, provided we are using the same models as the previous order.
Our team will advise which category your inquiry fits into and the estimated response time when acknowledging your inquiry.
As a contract manufacturer, our pricing is based on an order-by-order basis. This will always differ between post processing needs, lead time expectations, and any sub-contractor work needed.
We strive for transparency at Zenith Tecnica and have determined a minimum build recovery cost that must be met on a per-order basis. For our customers, this means that no formal quotes or cost estimates are going to be below a minimum charge of $2,650 NZD.
It is still important to note that it is based purely on order lot and NOT individual unit price. You will still be able to place orders with units valued under the minimum charge as long as the order lot volume meets or exceeds it.
EBM offers a large and highly productive build volume compared to other powder-bed AM technologies. Therefore, with higher quantity orders, the unit price can often drop dramatically as more components can be built at once.
Our team will always offer clear price breaks to ensure you are getting the most out of your order.
We have a proven track record of delivering urgent components worldwide and our team understands the urgent situations our customers often face.
We use express and urgent couriers that specialize in each region such as DHL and FedEx and have extensive experience in exporting goods to North America, the United Kingdom, and Australia.
Our team is also trained in U.S. export controls that cover EAR and ITAR classified digital files and items. Please contact us if you have any specific questions regarding export and shipping.
The lead time we quote will not include the time to ship the item(s) to you or any taxes or duties due upon the import of items. However, our team is trained in export compliance and we have processes in place to ensure that shipping goes as smoothly as possible. From our experience, the following guidelines apply:
International Shipping Guidelines
USA, Central and East Coast, 3-4 days
UK, 3-4 days
Australia, excluding WA, 1-2 days
Australia, WA, 2-3 days
New Zealand Shipping Guidelines
Rural Delivery, 1-2 days
As with all shipping, we cannot control if customs agencies decide to inspect or hold shipments or if there are courier delays, which may introduce additional time.
If you’ve still got a burning question that wasn’t answered above, feel free to get in touch and have a chat to the team. We are more than happy to talk through your questions and help find the answers you are looking for.