Direct Metal Laser Solidification (DMLS®) manufactures fully functional parts without the tooling and set-up time and costs affiliated with traditional manufacturing and casting. Manufacturing parts micro-layer by micro-layer enables highly complex designs to be produced in single pieces or with minimal assembly. i3DMFG™’s EOS M280, M290, M300.4 and M400.4 3D metal printing machines use 20 to 60 microns and 400W lasers to fuse micro-layer together at specific points directed by a 3D Solidworks design file. The powdered metal is spread by a sliding recoater arm on the print platform, laser fused, and then lowered by a distance equal to a single micron powder layer. This entire process is repeated on tens of thousands of layers until a fully functional production part is finished and ready to be Wire EDM precision cut from the build platform.

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. In many cases, the rapid solidification rate, after the laser fusing, creates a very fine crystal structure with superior strength to forged or cast components. When heat treated, density, durability, and strength are even greater. Because of the superior quality and unique manufacturing process, parts design freedoms include designs that are built hollow, or with fill structures that produce even higher strength-to-weight ratios.

i3DMFG™ specializes in advancements in DMLS® 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. i3DMFG™ invested in tools and partnerships that allow us to create custom metal powders and the corresponding computer programs (parameter sets).

i3DMFG™’s EOS M280 and M290 DMLS® machines use 20 to 60 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.

In addition to customized programming for new metal powders, i3DMFG™ and EOS have teamed up to take the M280 and M290, 3D metal printing machine capabilities to new heights in wall thickness, tolerances, varying layer thicknesses and part densities. As 3D printing moves beyond rapid prototyping and into production parts, i3DMFG™ makes sure it has the tools to meet its client’s traditional and next generation research and production needs.

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.