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Direct metal laser sintering
From Wikipedia, the free encyclopedia
Direct metal laser sintering (DMLS) is an additive manufacturing technique that uses a laser as the power
source to sinter powdered material (typically metal), aiming the laser automatically at points in space defined by
a 3D model, binding the material together to create a solid structure. It is similar to selective laser sintering
(SLS); the two are instantiations of the same concept but differ in technical details. Selective laser melting
(SLM) uses a comparable concept, but in SLM the material is fully melted rather than sintered, allowing
different properties (crystal structure, porosity, and so on). DMLS was developed by the EOS firm of Munich,
Germany.
[1]
The DMLS process involves use of a 3D CAD model whereby a .stl file is created and sent to the machines
software. A technician works with this 3D model to properly orient the geometry for part building and adds
supports structure as appropriate. Once this "build file" has been completed, it is "sliced" into the layer thickness
the machine will build in and downloaded to the DMLS machine allowing the build to begin. The DMLS
machine uses a high-powered 200 watt Yb-fiber optic laser. Inside the build chamber area, there is a material
dispensing platform and a build platform along with a recoater blade used to move new powder over the build
platform. The technology fuses metal powder into a solid part by melting it locally using the focused laser beam.
Parts are built up additively layer by layer, typically using layers 20 micrometres thick. This process allows for
highly complex geometries to be created directly from the 3D CAD data, fully automatically, in hours and
without any tooling. DMLS is a net-shape process, producing parts with high accuracy and detail resolution,
good surface quality and excellent mechanical properties.
Contents
1 Benefits
2 Applications
3 Constraints
4 Materials
5 See also
6 References
7 External links
Benefits
DMLS has many benefits over traditional manufacturing techniques. The ability to quickly produce a unique part
is the most obvious because no special tooling is required and parts can be built in a matter of hours.
Additionally, DMLS allows for more rigorous testing of prototypes. Since DMLS can use most alloys,
prototypes can now be functional hardware made out of the same material as production components.
DMLS is also one of the few additive manufacturing technologies being used in production. Since the
components are built layer by layer, it is possible to design internal features and passages that could not be cast
or otherwise machined. Complex geometries and assemblies with multiple components can be simplified to
fewer parts with a more cost effective assembly. DMLS does not require special tooling like castings, so it is
convenient for short production runs.
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Applications
This technology is used to manufacture direct parts for a variety of industries including aerospace, dental,
medical and other industries that have small to medium size, highly complex parts and the tooling industry to
make direct tooling inserts. With a build envelop of 250 x 250 x 185 mm, and the ability to grow multiple parts
at one time, DMLS is a very cost and time effective technology. The technology is used both for rapid
prototyping, as it decreases development time for new products, and production manufacturing as a cost saving
method to simplify assemblies and complex geometries.
[2]
The Northwestern Polytechnical University of China is using a similar system to build structural titanium parts for
aircraft.
[3]
An EADS study shows that use of the process would reduce materials and waste in aerospace
applications.
[4]
On September 5, 2013 Elon Musk tweeted an image of SpaceX's regeneratively cooled SuperDraco rocket
engine chamber emerging from an EOS 3D metal printer, noting that it was composed of the Inconel
superalloy.
[5]
Constraints
The aspects of size, feature details and surface finish, as well as print through error in the Z axis may be factors
that should be considered prior to the use of the technology. However, by planning the build in the machine
where most features are built in the x and y axis as the material is laid down, the feature tolerances can be
managed well. Surfaces usually have to be polished to achieve mirror or extremely smooth finishes.
For production tooling, material density of a finished part or insert should be addressed prior to use. For
example, in injection molding inserts, any surface imperfections will cause imperfections in the plastic part, and
the inserts will have to mate with the base of the mold with temperature and surfaces to prevent problems.
In this process metallic support structure removal and post processing of the part generated is a time consuming
process and requires use of EDM and/or grinding machines having the same level of accuracy provided by the
RP machine.
When using rapid prototyping machines, .stl files, which do not include anything but raw mesh data in binary
(generated from Solid Works, CATIA, or other major CAD programs) need further conversion to .cli & .sli
files (the format required for non stereolithography machines).
[6]
Software converts .stl file to .sli files, as with
the rest of the process, there can be costs associated with this step.
Materials
Currently available alloys used in the process include 17-4 and 15-5 stainless steel, maraging steel, cobalt
chromium, inconel 625 and 718, and titanium Ti6Al4V. Theoretically, almost any alloy metal can be used in this
process once fully developed and validated.
See also
List of notable 3D printed weapons and parts
3D printing
Additive manufacturing
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Desktop manufacturing
Digital fabricator
Direct digital manufacturing
Fab lab
Fused deposition modeling
Instant manufacturing, also known as "direct manufacturing" or "on-demand manufacturing"
Rapid manufacturing
Rapid prototyping
RepRap Project
Solid freeform fabrication
Stereolithography
Laser engineered net shaping
Laser sintering of gold
References
1. ^ "How Direct Metal Laser Sintering Works" (https://thre3d.com/how-it-works/powder-bed-fusion/direct-
metal-laser-sintering-dmls). THRE3D.com. Retrieved 3 February 2014.
2. ^ Additive Companies Run Production Parts (http://www.rapidtoday.com/rqm.html)
3. ^ "China commercializes 3D printing in aviation." (http://www.zdnet.com/cn/china-commercializes-3d-printing-
in-aviation-7000011377/)
4. ^ "EADS Innovation Works Finds 3D Printing Reduces CO2 by 40%" (http://3dprintinginsider.com/eads-
innovation-works-finds-3d-printing-reduces-co2-by-40_b11165). 3dprintinginsider.com. Mediabistro Inc.
Retrieved 7 November 2013.
5. ^ "Twitter" (http://www.twitter.com/elonmusk/status/375737311641628672?screen_name=elonmusk).
Mobile.twitter.com. Retrieved 2014-08-21.
6. ^ http://knowledge.stereolithography.com/activekb/questions/74/STL+File+Conversion
External links
Rapid Manufacturing's Role in the Factory of the Future (http://www.designnews.com/article/7233-
Rapid_Manufacturing_s_Role_in_the_Factory_of_the_Future.php)
Direct metal laser sintering (http://www.youtube.com/watch?v=bgQvqVq-SQU), video (2:34).
[1]
1. ^ Thu, 02/06/2014 - 10:41am (2014-02-06). "The Laser-Sintering Effect"
(http://www.rdmag.com/articles/2014/02/laser-sintering-effect). Rdmag.com. Retrieved 2014-08-21.
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Categories: Metalworking 3D printing
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