German machinery manufacturer ALD Vacuum Technologies has developed its novel EBuild 850 electron beam powder bed fusion (PBF-EB) system for production of large metal components.
At its core, the EBuild 850 uses an electron beam in a vacuum to melt metal powder within a build volume of 850 × 850 × 1000 mm³, enabling the production of components up to 1000 mm in height. The manufacturer has specified a maximum build rate of 1000 cm³/h, supported by a 45 kW electron beam. This makes the system ideal for use in sectors such as aerospace, pump manufacturing, and gas turbine production where large metal parts and high-temperature materials are required.
“Rather than removing material, as in milling, components are built layer by layer, with raw material selectively melted using a high-energy source such as a laser or an electron beam,” explains Dr. Alexander Klassen, Vice President of Additive Manufacturing at ALD.
A system built for scale
The machine is organized around a movable build chamber, a process chamber with a powder deposition unit, and a separate extraction unit for powder preparation and part removal. To increase utilization, an optional second build chamber allows one chamber to be prepared while another is running. Inside the system, the powder bed can weigh up to 15 t and is positioned by a withdrawal unit with a stated repeatability of approximately 0.01 mm across the full 1000 mm build height.
During production, powder is applied in layers and selectively melted as the electron beam follows predefined toolpaths, with magnetic deflection used for beam steering. The system is designed for sustained high thermal loads, incorporating heat shields, water cooling, and sensors, moving assemblies, and powder handling elements rated for elevated temperatures and metal dust environments.
The EBuild 850 operates within a stated temperature range of 700–1200 °C, allowing it to process materials such as titanium alloys including Ti-6Al-4V, nickel-based alloys, and titanium aluminides. Running at these temperatures is intended to reduce residual stresses that can arise during metal additive manufacturing, particularly in large or geometrically complex components.
Powder handling is addressed as a core element of the system’s overall design. The EBuild 850 is intended to process powders with a broader particle size distribution than is typically required for PBF. This enables the reuse of excess powder from in-house production as well as off-spec material from powder suppliers. According to ALD, the combination of beam power, process control, and thicker melt layers supports stable processing even when powder batches are not fully uniform.
Process monitoring is integrated directly into the build workflow rather than treated as a separate inspection step. The electron beam is used to observe each layer as it is produced, following a principle comparable to scanning electron microscopy. This allows process deviations or defects to be identified during the build itself and adjustments to be made before the part is completed.
Technical specifications and pricing of the EBuild 850 3D printer
Interested readers can contact the company or visit the ALD Vacuum Technologies website for more details.
| Product | EBuild 850 |
| Acceleration Voltage | max. 150 kV |
| Power | max. 45 kW |
| Build Area | 850 x 850 mm |
| Build Height | max. 1000 mm |
| Powder Bed Temperature | max. 1200 °C |
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Featured image shows ALD Vacuum Technologies’ EBuild 850 PBF-EB system installed in an industrial production environment. Photo via ALD.
