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Direct Metal Laser Sintering and Melting

DMLS

Direct metal laser sintering and melting, or DMLS/DMLM, is the process of manufacturing metal parts from 20-40-micron powders with 400W lasers. These lasers fuse microlayers of fine metal together to create complex geometries from 3D design files. Because direct metal laser sintering melts and forges metal powders repetitively, the process ensures 99.9% uniquely uniform densities throughout the parts.

The powdered metal is first spread by a sliding arm on the print platform. Then, the powdered metal is laser fused and 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 formed. Once the process is finished, the part is ready to be Wire EDM precision-cut from the build platform.

Direct metal laser sintering machines produce parts that are known for their strength, hardness, and densities–each of which are comparable to or better than those of machined, cast, or forged parts of similar metals. 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. If the DMLS/DMLM part is heat treated, its density, durability, and strength are even greater.

Because of the superior quality and unique manufacturing process, direct metal laser sintering machines allow for design freedom. Designs can be built hollow or filled for even higher strength-to-weight ratios. From aerospace to firearms, find out how DMLS/DMLM can is used in your industry.

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 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.

Visit Our DMLS Library

Aluminum (Al)

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.

Titanium (Ti)

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

Stainless Steels

DMLS/DMLM 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, and .316. Parts made from DMLS/DMLM can be machined, spark-eroded, welded, micro shot-peened, polished, and coated.

Maraging Steel

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.

Inconel (IN718)

IN718/INC625 are chromium alloys with superior heat resistance and a typical heat treatment hardness of 40-47 HRC (370-450HB).

Custom Powders

i3D MFG™ is the market leader is DMLS powder development. We are able to develop highly specialized powder applications for aerospace, UAV/UAS, rocket, defense, firearms, oil & gas, energy, medical device, automotive, and casting customers.

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