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3D Metal Printing – DMLS®

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, 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.

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.

Production AM

EOS M400.4

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.

EDM

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.

Metals We Print

i3DMFG is one of the few 3D manufacturers in the US that specializes in aluminum, copper, titanium, Inconel, Haynes, Monel K, Stainless Steel and custom metal powder applications. Experts in 3D design, our engineers help our customers achieve competitive advantage in design and proprietary advancements.

Metals We Print

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 (Ti)

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

Stainless Steels (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 Nickle Alloys (IN625, IN718, Haynes 214, 242, 282 and Hastelloy X)

Super Nickle alloys are chromium alloys with superior heat and corrosion resistance.

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.

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