DIRECT METAL

LASER SINTERING(DMLS)
 Introduction:
What is Rapid Prototyping ?
Rapid prototyping is a group of techniques used
to quickly fabricate a scale model of a physical
part or assembly using three-dimensional
computer aided design (CAD) data.

Fig-1 CAD Model Fig-2 Finished Part

 History
he roots of Rapid Prototyping can be traced to Topography &
Photo sculpture
opography was first proposed by Blanther in 1890.
hoto sculpture for 3D replicas of objects were proposed by Bogart
n 1969.

Fig-3: Fig-4: Photo

Topography sculpture 3D
 Fundamentals of Rapid Prototyping
RP techniques employ the some basic five-step process
1.Creating the 3D CAD model of the design

2.Converting the CAD model into STL format (stereo

lithography)
3.Slicing the STL file into thin cross-sectional layers

4.Constructing the model one layer atop another

5.Cleaning and finishing the model

1 2.
.

3. 4.

5.

Fig-5: Basic Steps in RP Technology

 Classification of RP Systems
1. Liquid-Based
2. Solid-Based
3. Powder-Based
 Direct Metal Laser Sintering (DMLS)
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.
 Working
principle:

Fig-6: Step by step procedure of DMLS

 Metal Powders used
Stainless steel Titanium
17-4 Ti-64

Aluminum Nickel alloy IW

718
 Advantages of
DMLS
High speed: Because, no special tooling is required,
parts can be built in a matter of hours.
Complex geometries: Components can be designed
with internal features and passages that cannot be
cast or otherwise machined.
High quality: DMLS creates parts with high
accuracy and detailed resolution.
 Application
Medical field Aerospace Industries

Automotive
Manufacturing
 Limitations
Surfaces need to be polished.
Removing metal support structures and thermal post-
processing is time consuming (you cant have the
supports in a different material than the part)
 Case Study
Titanium glasses using metal additive manufacturing

Fig-7: Titanium
The eye venture decided
glassesto look into the possibility of using
additive manufacturing in titanium as this eliminated the
need for tooling and also allowed flexibility in future
interchangeable designs of the frame can be made by CAD
data and the parts rebuilt quickly and cost effectively.
 Conclusion
The DMLS uses high intensity laser source and imparts the energy over the
metal powder as per the required geometry pattern ,melts below its melting
point and solidifies the metal powder to the deposited layer without affecting
the material properties.
DMLS process used for the actual material needed to make the part at one
build time, there by eliminates the secondary machining.
DMLS eliminates tool change & production line cost resulting in small batch
& single part build cost efficiency.
Thank
you