EWI Highlights Its Wayland Calibur3 Electron Beam Powder Bed Fusion Technology!

EWI, a technology leader based in Columbus, Ohio, is drawing attention to its new Wayland Additive Calibur3 Electron Beam Powder Bed Fusion (PBF-EB) machine installed at its Buffalo Manufacturing Works facility. At present, EWI is the only organization in the United States with access to this advanced Additive Manufacturing technology, making it a unique resource for American industry. The Calibur3, powered by Wayland’s NeuBeam process, represents a significant advancement in the field of electron beam-based additive manufacturing.

One of the core advantages of the Calibur3 system is the NeuBeam process, which overcomes one of the longest-standing challenges in PBF-EB technology: charge buildup and powder scattering, commonly referred to as “smoking.” In traditional electron beam systems, the powder bed accumulates a negative charge during builds. Over time, this charge can cause the powder to scatter, disrupting builds and contaminating the chamber. Conventional systems attempt to mitigate this by sintering entire powder layers before melting the part geometry. While this approach reduces smoking, it adds significant drawbacks including difficult powder recovery, lengthy post-processing, and restrictions on design freedom.

Wayland’s NeuBeam process addresses the issue directly by introducing a small amount of positively charged argon ions into the build chamber. These ions neutralize the negative charge on the powder, preventing smoking events altogether. This innovation eliminates the need to sinter entire powder layers, thereby simplifying powder recovery, reducing post-processing, and enabling greater design flexibility. For manufacturers, this means cleaner parts, faster production, and a more efficient workflow.

Unlike laser-based systems, which rely on mechanically controlled mirrors, the Calibur3 uses a high-energy electron beam that is magnetically steered. This allows for much faster and more precise beam control, with the capability to move orders of magnitude quicker than a laser system. The result is greater energy transfer and deeper penetration, supporting higher-temperature builds, larger layer heights, and improved control of material microstructure. Because the process operates under vacuum conditions, oxidation is minimized, which is especially important for sensitive materials.

EWI has already validated the benefits of the Calibur3 by conducting dozens of successful builds using recycled powder with minimal degradation. This not only demonstrates the system’s ability to produce high-quality parts consistently but also highlights its potential for sustainable and cost-effective additive manufacturing. The machine has been tested with a variety of materials, including molybdenum, titanium alloys such as Ti64, and niobium alloys like C103. Results have shown near full-density builds with minimal porosity in refractory metals like molybdenum and high-strength, complex geometries in aerospace-grade titanium alloys.

The ability to build complex geometries without the limitations of full-layer sintering further enhances the Calibur3’s value. Parts can be removed more easily from the powder bed, internal features can be more intricate, and powder recovery is cleaner and more efficient. These advantages lower waste and contribute to overall cost savings.

Moving forward, the EWI team plans to use the Calibur3 to expand proof-of-concept builds, refine control over microstructure through tailored build parameters, and evaluate recyclability and long-term consistency for production environments. With its unique capabilities and access to NeuBeam technology, EWI is positioning itself as a leading resource for industries exploring the next generation of electron beam additive manufacturing.