2024 in review

2024 was a decisive year for additive manufacturing and also for OSCAR-PLT. The advance of DED technologies was noticeable everywhere, not least at this year’s Formnext, where the growing demand for high-quality DED solutions was clearly noticeable. Even in economically uncertain times, there is a global need for high-performance future technologies that impress with their reliable quality and uncomplicated handling.

We have celebrated many highlights over the past twelve months, and here we present our top 5 of the year – with a big thank you to all our customers, partners and team members. Together we make the impossible possible!

1. System of the year: ProFocus LaserCell

An industrial robot welding cell using a directed energy deposition (DED) technology called Wire Laser Metal Deposition (LMD-w).

The ProFocus LaserCell is our future-proof all-in-one solution for production, repair and coating. With a 6-axis robot and state-of-the-art process control, this system is designed for maximum flexibility and precision. Intuitive operation and functions such as Path Planning, StartControl and the WireWatcher ensure maximum process stability and efficiency. Whether small components or large workpieces – the LaserCell masters every challenge.

2. Application study of the year: Wear protection for hydraulic components

A photo of a laser weld head applying metal wear protection to a component

A real milestone: Together with our partner Metrom, we have coated a hydraulic component made of GJS-600 for use in open-cast mining vehicles. This application offers a crack-free coating hardness of 65 HRC and replaces environmentally harmful hard chrome plating. The component is currently being tested in open-cast mining and is showing impressive results in terms of durability and wear protection. This solution proves how sustainable technologies can replace traditional methods.

3. Software development of the year: Scanner integration

A photo of a laser head scanning a component as part of an additive manufacturing process.

Our cooperation with S.K.M. Informatik has taken our systems to a new level. With scanner integration, component geometries can be captured directly in the coordinate system of the laser cell and compared with target geometries. This technology enables precise path planning, particularly in 3D repair applications where worn components no longer provide complete data. The advantages? Time savings, precise results and even more efficient repairs.

4. 3D repair of the year: 1970 seal housing

Two images of a component, before and after a 3D repair using directed energy deposition (DED) technology called Wire Laser Metal Deposition (LMD-w).

We repaired a water-cooled seal housing for a hydraulic cylinder in a blast furnace for Hansa-Flex – a component that has not been produced since 1970.The repair required a precise choice of material in order to fulfil the different thermal expansion coefficients. The inner housing was coated with a copper-based alloy, while the outer surfaces were reworked from mild steel. This measure impressively demonstrates how additive repair processes can extend the service life of components.

5. Hardware development of the year: ProFocus LaserCell Compact

A 3D Rendering of a laser cell used for industrial metal 3d printing and 3d repairs.

The ProFocus LaserCell Compact is currently under development and will provide the ideal solution for feasibility studies and the production of small components. With an ultra-light laser head weighing just 6 kg, the system is exceptionally flexible and precise. Even difficult materials such as aluminium or copper alloys can be processed with ease. In particular, the reliability and user-friendliness of this space-saving system will help customers to make their production faster and more cost-efficient.

Looking ahead to 2025: With these successes behind us, we look forward to working with you on the challenges of manufacturing in the coming year.