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Green Laser Metal 3D Printing Transforms the Future of Induction Coil Manufacturing

With ongoing industrial and technological advancements, there is a growing demand for components with greater structural complexity and higher performance requirements. Pure copper high-frequency induction heating coils serve essential functions in precision applications such as quenching, annealing, brazing, and rapid melting. These coils often feature intricate internal channels that are challenging to manufacture. Traditional assembly and welding methods are inefficient and commonly lead to issues such as unstable electrical conductivity and poor resistance to thermal cycling, posing challenges to meeting the precision and reliability standards of advanced manufacturing. To ensure optimal performance while enabling cost-effective, rapid mass production, the industry is increasingly turning to additive manufacturing. Metal 3D printing is emerging as a breakthrough solution, offering direct one-step manufacturing of complex structures and achieving cost optimization for pure copper induction coils.

To address challenges including non-uniform resistance and reduced thermal dissipation efficiency commonly associated with traditional manufacturing methods, metal 3D printing offers an effective solution. This technology enables the one-step manufacturing of complex high-frequency induction coil geometries, eliminating contact resistance and weld-related defects, and enhancing performance and structural stability. ADDIREEN's green laser (λ = 532nm) 3D printing technology, leveraging the high absorption rate of pure copper at shorter wavelengths (exceeding 40% in the solid state), significantly improves both printing efficiency and the quality of printed parts compared to conventional laser-based methods.

ADDIREEN has successfully manufactured pure copper high-frequency induction coils with exceptional density and performance using green laser metal 3D printing. The resulting components exhibit the following key properties:

￭ Densification ≥ 99.8%

￭ Electrical conductivity ≈ 101% IACS

￭ Thermal conductivity ≈ 390 W/(m·K)

Powered by the fine-spot precision of green laser technology, ADDIREEN's high-resolution printing capability enables precision manufacturing for industrial heat treatment applications. This allows for the production of long-life, customizable induction heating solutions that significantly improve both manufacturing efficiency and end-product performance.

ADDIREEN Green Laser 3D Printing Technology

ADDIREEN's green laser 3D printing technology specializes in Laser Powder Bed Fusion (L-PBF) of highly reflective and refractory metals such as pure copper and copper alloys. Based on a powder-bed fusion process, each coil is constructed through the layer-by-layer deposition of metal powder, which is selectively melted by a green laser. This process eliminates post-print welding and yields high-density, high-precision coil structures.

Extended Lifespan

The L-PBF process enables the manufacturing of complex structures in a single build, effectively eliminating issues related to weld joint failure. The pure copper powder features an ultra-high purity of 99.95% with an oxygen content below 20 ppm. Printing is conducted under an inert atmosphere to ensure high-density, stable build quality and to minimize the risk of oxidation. As a result, the final printed coils exhibit no structural weak points, leading to a significantly extended service life.

Lower Cost Production

The green laser PBF process eliminates the need for tooling and multi-step post-processing, enabling the on-demand manufacturing of complex structures without the use of molds. This technology replaces traditional methods involving cutting, splicing, and welding, significantly reducing labor and material waste. Therefore, the elimination of post-assembly steps streamlines the entire production workflow and reduces overall manufacturing costs.

Optimized and shortened development period

Green laser metal 3D printing is a highly efficient process that enables rapid design and optimization of induction coil geometries. Pure copper's high absorption of green laser energy at a wavelength of 532nm makes the manufacturing of complex structures significantly more efficient and reliable. The newly developed coils not only meet the same quality standards as conventionally manufactured components but also accelerate the product development cycle, reducing lead times from weeks to just days.

The high absorption of green laser energy by copper-based materials, combined with the green laser's fine spot size and precise detail control, makes ADDIREEN's XH-M160G, XH-M350G, and other green laser metal 3D printing systems ideal for the rapid and precise manufacturing of complex pure copper structures. Following process parameter optimization, the mechanical properties of the pure copper high-frequency induction coils approach the material's theoretical limits. The tested cycle life is at least twice that of conventionally fabricated coils. The streamlined production process also significantly reduces manufacturing costs. These advancements enable the delivery of green laser solutions with superior performance, improved efficiency, and greater competitiveness.

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