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Direct Metal Laser Solidification (DMLS®) 3D Printing in the Energy Industry

i3DMFG 3D Printing Energy Industry

i3DMFG™ is proud to be the first DMLS® provider in North America to own the EOS M280, M290 & M400 x 4. We pride ourselves on our DMLS® metal powder development and 3D printing for the energy and oil & industries. i3DMFG™ is an official Material Process Applications (MPA) site for EOS.

Our DMLS® 3D printers manufacture parts using a 3D CAD model-driven machine to fuse microlayers of powder together using 400W lasers. Products are built layer by layer and can include internal cooling channels, curved features, and lattice and honeycomb geometries that would otherwise be impossible or too expensive in traditional manufacturing. Our DMLS® 3D printers also construct fully functional production parts in a matter of days rather than months, giving customers competitive advantages in time-to-market, product development, and small batch production.

3D printing in the energy industry often includes products made from copper, aluminum, maraging steel, stainless steel, Inconel, and titanium. We also print in exotic metals such as Monel K 500 upon request. DMLS® parts can be post-processed similarly to cast or machined parts, from polishing to welding and anodization.

Oil & Gas Industry

In Haliburton and GE’s Oil & Gas divisions, the use of DMLS® has already begun. Due to 3D models drive 400W lasers to fuse micro-layers of powder together in linear and organic shapes, 3D metal printing eliminates traditional design-for-manufacture constraints. Complex internal geometries, conformal cooling channels, micro-channels, latticed and honeycombed designs, and free-form shapes are all manufacturable and economical since the DMLS® part is grown layer by layer, in tens of thousands of layers.

Parts are manufactured in days instead of months with i3DMFG™’s DMLS® production. This reduces part inventory requirements and allows for custom, one-off part solutions. The oil and gas industry is very competitive, which makes time and innovation incredibly valuable. We on-shore everything to protect designs, costly tool change times, and shipping costs.

Clean Energy

Creating production parts for the clean energy industry using DMLS® is a cost-effective and flexible option for manufacturers in the United States. Our DMLS® 3D printing process builds innovative components layer by layer, creating designs that would be too costly or impossible to manufacture via machining or casting. Held tolerances are up to +/- 0.002, allowing for precision and post-processing to even tighter tolerances. All DMLS® production is done on-shore to protect our customer’s designs and increase speed-to-market and product testing costs.

Heat Exchangers

Efficient fluid flow and heat transfer are critical in the Heat Exchanger industry. i3DMFG™’s DMLS® innovations allow for complete assemblies to be manufactured as a single metal part. Because DMLS® parts are 3D printed in thousands of micro-layers, there are unlimited options for engineers to incorporate fluid circuits built one inside the other, concentric fluid circuits, curved features for improve fluid flow, and lattice and honeycomb geometries. Welds, gaskets and joints can also easily be eliminated.

Metals We Print

In the U.S., i3DMFG™ offers one of the largest selections of DMLS® standard metal powders. As an EOS MPA (Material Process Applications) site, we are one of the few 3D manufacturers specializing in copper, titanium, Inconel, Haynes, Monel K, Stainless Steel and custom metal powder applications. Our customers recognize our significant competitive advantages in design and proprietary advancements due to our engineers being experts in Design-for-3D strategies.

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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, Haynes 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, firearms, oil & gas, energy, medical device, automotive, and casting customers.

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