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3D Direct Metal Laser Solidification (DMLS®) Services

i3DMFG™ specializes in additive manufacturing, or Direct Metal Laser Solidification (DMLS®) services. Our expertise in metal 3D printing extends beyond rapid prototyping and expands into production parts. Each component that we fabricate is crafted with precision using DMLS® metal powders and continual process development. Industries, including the aerospace, UAV/UAS, defense, medical device, oil & gas, energy, and automotive industries, utilize our DMLS® services. Our team of Pacific Northwest natives treat each client with the same care and respect that we grew up with. For all of your DMLS® printing needs, look to the professionals at i3DMFG™. Fill out our online form for a quote.

DMLS® Metal Powders

Material Process Applications

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).

DMLS®

Direct Metal Laser Sintering M290

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.

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.  i3DMFG™ uses its 3D scanner to inspect each part to insure specification conformance.

i3DMFG™ Metals

Stock Powders

Aluminum (AlSi10 and 6061)

Due to its lightweight nature and excellent thermal properties, AlSi10 is our most common DMLS aluminum powder. It is ideal for parts with thin walls and complicated geometries. i3DMFG™ also runs 6061 to achieve better surface finish and strength properties comparable to wrought 6061-T6.

Titanium (Ti64)

Titanium (Ti64) is well suited for projects requiring corrosion resistance, strength, weight reduction, and biocompatibility.[/

Stainless Steel (15-5, 17-4, 304L, and 316L)

DMLS® stainless steel is a medical grade, sterilisable, corrosion resistant steel that hardens to 40-45 HRC after heat treatment. Our stainless-steel equivalents include 15-5, 17-4, 304L, and 316L. Parts made from DMLS® can be machined, spark-eroded, welded, micro shot-peened, polished, and coated.

Maraging Steel (MS1)

Maraging (tool) Steel (MS1) features excellent strength and mechanical properties. 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.

Super Ni Alloys (IN625, IN718, Haynes 214, Haynes 282, Hastelloy X and Monel K 500)

[ “]These Nickel/Chromium Super Alloys have superior heat and corrosion resistance and can have a typical hardness of 40-47 HRC (370-450HB).  Rocket, space, aerospace, defense, energy, and automotive industries rely on Super Ni Alloys.

Copper (GrCop-84 and GrCop-42)

i3DMFG™ is developing parameter sets to print in GrCop-84 and GrCop-42 for high temperature applications.

A NASA developed Copper alloy that is highly conductive for the aerospace industry.

 

Custom Powders

i3DMFG™ is the market leader is DMLS® powder development. We are able to develop highly specialized powder applications for aerospace, UAV/UAS, rocket, defense, oil & gas, energy, medical device, automotive, and casting customers.

Why Choose i3DMFG™

i3DMFG™ focuses solely on DMLS®. Our days are filled with specialized 3D metal printing applications. We take pride in being Oregon’s premier 3D metal manufacturer.

Specialized DMLS® Applications

i3DMFG™ is a premier EOS service provider. We specialize in M290 and M400.4 DMLS® metal powder development as well as DMLS® parameter set customization. i3DMFG™ 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

i3DMFG™ 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.

Efficient, Flexible Production

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

i3DMFG™ is proud to have been one of the first North American manufacturers to own the EOS M290 DMLS® machines, along with our production M400.4 machines. Combined with our tried and true EOS M280, i3DMFG™ customers have the best of both worlds for DMLS® 3D manufacturing capabilities.  We also offer in-house Wire EDM, 3D Blue Light Scanning, Stress Relieve, 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 i3DMFG™ clients a competitive advantage in market testing, product improvement reaction time, and JIT delivery.

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