I3DMFGI3DMFG

i3D MFG™ Direct Metal Laser Sintering

DMLS

Direct Metal Laser Sintering (DMLS)

i3D MFG™’ exclusively utilizes EOS M280 and M290 Direct Metal Laser Sintering (DMLS) machines to manufacture metal parts from 20-40 micron powders with 400W lasers that fuse micro-layers of fine metal together to create complex geometries from 3D design files. DMLS parts are typically characterized as having strength, hardness and densities comparable to or better than machined, cast and forged parts in comparable metals. The metal powder is melted and forged over and over again, creating 99.9% uniquely uniform densities throughout the parts.

The powdered metal is spread by a sliding 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.  Click here to see how DMLS works for various industries.

EOS DMLS M280

Direct Metal Laser Sintering M280

The EOS M280 is the work horse of EOS DMLS (Direct Metal Laser Sintering) 3D printers. It produces production parts using fully automated laser sintering driven by Solidworks CAD files, no CNC programming, no tool changes necessary.

Constant system self-monitoring of the build process ensures that all parts are printed in fully functional, reproducible quality. 3D metal printing allows clients to design and manufacture products with extremely complex geometries including free-form surfaces, lattice and honeycomb structures, deep slots, and conformal cooling channels.

The Basics

  • 3D Manufacturing of metal, fully functional, production parts
  • Aluminum, Titanium, Inconel, Maraging (Tool) Steel, Stainless Steel in stock
  • Open parameter sets for custom powder and 3D production efficiencies
  • Cost efficient manufacturing of high quality metals is small to medium-size runs
  • Reduce weight by 70% with latticed & honeycomb geometries
  • Reduced lead times to hours, days or weeks
  • Rapid prototyping and manufacturing made easy with Solidworks, Raw files, and .Step files

Key Statistics

  • Net build size: 228 x 228 x 190 mm (9 x 9 x 7.5 inches)
  • Minimum Feature size = .015’’ or .38 mm
  • Minimum wall thickness is .3mm – .4mm or .012” – .014”
  • Layer Thickness = 20 or 40 microns
  • Typical held tolerances are +/- .005″ on 1st in, +/- .002″ thereafter

EOS DMLS M290

Direct Metal Laser Sintering M290

i3D MFG™ is proud to have the first EOS M290 DMLS machine in North America. The EOS M290 is the latest in DMLS (Direct Metal Laser Sintering) excellence. Using the highly reliable M280 as it base, the M290 adds improved energy efficiencies, faster build times, and slightly larger build platform capabilities. i3D MFG™ clients gain the benefits of years of M280 proven applications while accessing the latest in DMLS technology.

The Basics:

  • 3D Manufacturing of metal, fully functional, production parts
  • Aluminum, Titanium, Inconel, Maraging (Tool) Steel, Stainless Steel in stock
  • Open parameter sets for custom powder and 3D production efficiencies
  • Cost efficient manufacturing of high quality metals is small to medium-size runs
  • Reduce weight by 70% with latticed & honeycomb geometries
  • Reduced lead times to hours, days or weeks
  • Rapid prototyping and manufacturing made easy with Solidworks, Raw files, and .Step files

Key Statistics:

  • Net build size: 250 x 250 x 300mm
  • Minimum Feature size = .015’’ or .38 mm
  • Minimum wall thickness is .3mm – .4mm or .012” – .014”
  • Layer Thickness = 20 or 40 microns
  • Typical held tolerances are +/- .005″ on 1st in, +/- .002″ thereafter

Metals We Print

i3D MFG™ offers one of the largest selections of DMLS standard metal powders in the U.S. We are one of the few 3D manufacturers specializing in Titanium and Inconel and are the EOS North America MPA (Material Process Applications) partner specializing in custom metal powder applications. Our engineers are experts in Design-for-3D strategies, enabling our customers to realize significant competitive advantages in design and proprietary advancements.

Visit Our DMLS Library

Aluminum (Al)

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.

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 Steels

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

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.

Got A Question? We Are Here To Help!

  • 3525 Crates Way, The Dalles, OR, 97058
  • 541.588.0986
  • [email protected]