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i3D™ Specializes in Additive Manufacturing (DMLS Printing Services).  Our expertise in metal 3D printing extends beyond rapid prototyping and into production parts by way of metal powder and process development.  Our team of Pacific Northwest natives treat our clients with the same care and respect that we devote to enjoying the quality of life we grew up with.

Material Process Applications

Material Process Applications

i3D MFG™ specializes in advancements in DMLS (Direct Metal Laser Sintering) metal powder development, process refinement, and production applications. Our unique focus on production solutions makes us the North America EOS MPA (Material Process Applications) site partner.  i3D MFG™ invested in tools and partnerships that allow us to create custom metal powders and the corresponding computer programs (parameter sets).

Direct Metal Laser Sintering

Direct Metal Laser Sintering M290

i3D MFG™’s EOS M280 and M290 Direct Metal Laser Sintering (DMLS) machines use 20 to 40 micron powders and 400W lasers to fuse micro-layers of fine metal together at specific points directed by a 3D Solidworks design file to produce production parts. DMLS parts are typically characterized as having strength, hardness and durability that is, at the least, comparable to cast or forged parts in a comparable metal.

Electrical Discharge Machining

Electrical Discharge Machining

Electrical Discharge Machining (EDM) is a precision manufacturing process through which, a desired shape is cut to held tolerances of up to +/- .001mm using electrical discharges across a fine wire. With minimal set-up time for intricate cutting patterns, the CUT 30P is a perfect complimentary manufacturing process.  Many of our customers have found that their less complex, but high tolerance parts are well-suited to production on the Wire EDM.

Blue Light 3D Scanning Technology

Blue Light 3D Scanner

Our 3D scanner performs surface height measurements of parts using Coherence Scanning Interferometry (CSI) using spectrally-broadband (‘blue-light’) illumination. 3D scanning is also a useful tool for FEA analysis, reverse engineering, obsolete part re-creation, and quality assurance measures.  i3D MFG™ uses its 3D scanner to inspect each part to insure specification conformance.

i3D MFG™ Metals

Stock Powders

Aluminum (Al)

AlSi12 isn our most common DMLS Aluminum powder and is perfect for projects with good thermal and low weight considerations.  It is an optimal metal for parts with thin walls and complex geometries.

Titanium (Ti)

Ti64 is the standard DMLS powder which is well suited for Medical, Aerospace, Firearms, Energy and Automotive projects requiring corrosion resistance, strength, weight reduction and biocompatibility.

Stainless Steel PH1

PH1 is a medical grade, sterilisable, corrosion resistant steel. It is primarily used in Medical, Firearms, Energy and Automotive applications. After heat treatment, PH1 hardens to 40-45 HRC. Our stainless steel equivalents include 15-5, 17-4, and .316. Parts made from EOS StainlessSteel PH1 can be machined, spark-eroded, welded, micro shot-peened, polished and coated if required.

Maraging Steel MS1

Our maraging steel powder has excellent strength and mechanical properties. MS1 is a pre-alloyed, ultra high strength steel powder most commonly used for tooling applications. Its chemical composition corresponds to U.S. 18% Ni Maraging 300, European 1.2709 and German X3NiCoMoTi 18-9-5. After heat treatment, MS1 typically has a 50-53 HRC.

Inconel (IN718)

IN718 is a DMLS nickel; A Chromium alloy with superior heat resistance and typical heat treatment hardness of 40-47 HRC (370-450HB).  Rocket, space, aerospace, firearms, energy, and automotive industries rely on Inconel.

Custom Powders

i3D MFG™ is the market leader is DMLS powder development. In addition to our established metallurgical partnerships, i3D™ is the first North American EOS Material Process Application (MPA) Development Partner, giving us access to the latest DMLS machine parameter sets and enabling i3D™ to develop highly specialized powder applications for aerospace, rocket, automotive, and casting customers.

Why Choose i3D MFG™

i3D MFG™ takes DMLS beyond rapid prototyping and production parts to the next evolution of additive manufacturing

Material Process Applications

i3D™ is the first official EOS DMLS Applications partner.  We specialize in new M290 DMLS metal powder development as well as DMLS parameter set customization. i3D™ looks at the laser transitions on the part geometry layer by layer to analyze expected performance.  From that we develop variations from standard material parameters to meet specific application requirements

Design-for-3D-Expertise

i3D™ assists our client’s designers and engineers in Design-for-3D manufacturing.  Design-for-3D manufacturing creates limitless new opportunities for game-changing new parts and efficiencies including highly complex geometries, inserts during build process, lattice and honeycomb features, density and porosity extremes, micro channels and conformal channels, free-form organic shapes, and single part print of multi-print assemblies

Affordable, Flexible R&D

DMLS enables proof-of-concept to fully functional part production in weeks or months.  This allows us to do easy model tweaks in hours, cost effective single part production, small batch production, multiple designs on one build, and multiple parameters on one build
Why Choose i3DMFG

Latest DMLS Technology

i3D™ is proud to be the first North American manufacturer to own the new EOS M290 DMLS machine.  Combined with our tried and true EOS M280, i3D™ customers have the best of both worlds for DMLS 3D manufacturing capabilities.  We also offer in-house Wire EDM, 3D Blue Light Scanning, Heat Treatment, and post process finishing technologies

Cost Effective Small Batch

DMLS eliminates tool change and production line NRE costs, resulting in small batch and single part build cost efficiencies.  The no-waste additive process eliminates 50-70% of material scrap waste, reducing material costs.  Multiple separate project or client 3D CAD models can run on a single build, enabling economies of scale within projects, between projects, and even amongst different customers

Speed To Market

Parts and small batch test runs can be 3D printed in hours and post-processed to any finish requirements in days.  Design changes are possible in hours with revised fully functional parts delivered in days.  This type of nimble market reaction time gives i3D™ clients a competitive advantage in market testing, product improvement reaction time, and JIT delivery

DMLS PROCESS OVERVIEW

Transfer 3D Files to i3D™

Your design our ours, i3D™ reviews and assists in optimizing your part for 3D printing.  We accept .Sldprt, RAW, and .Step files.  We convert and print from .stl

DMLS 3D Print Process

Your part files are sent to our M280 or M290 for printing in Aluminum, Titanium, Inconel, Tool Steel, or Stainless Steel.  i3D™ will make suggestions to optimize surface finish and post process requirements.

Part Post Process

After the parts are heat treated they are cut from the build plate on i3D™’s Wire EDM machine, finished to specification and shipped per instructions.

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