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).
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 (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.
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.
AlSi12 is 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.
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.
Our Stainless Steels are 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. Parts made from DMLS Stainless Steel can be machined, spark-eroded, welded, micro shot-peened, polished and coated if required. Our stainless steel equivalents include 15-5, 17-4, 304L, 316L.
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.
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, firearms, energy, and automotive industries rely on Super Ni Alloys.
We are proud to partner with powder industry leaders AMA and Praxair. Their metallurgical expertise combined with i3D’s custom parameter recipes, enables our clients to print in new and emerging metals and push the limits of DMLS technology.
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<
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
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
i3D™ is proud to have been one of the first North American manufacturers 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
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
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
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