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DMLS & DMLM 3D Printing for the Medical Device Industry

i3DMFG 3D Printing For Medical Industry

3D printing using DMLS and DMLM medical-grade stainless steel and titanium allows for the development of tailor-made products according to patient scans and freeform designs that cannot be traditionally machined. 3D printed medical implants and other products can incorporate lattice design structures that encourage bone and tissue growth, which minimizes rejection rates and conforms easily with the human body. DMLM and DMLS 3D printing also allows for cost-efficient small batch production. Rapid prototyping and quick turn production allows medical suppliers and designers to service physicians and hospitals with flexible JIT delivery and responsive lead times.

Dental Implants

There is no need for expensive tooling or set-up costs with DMLM/DMLS. 3D dental implants can be printed with tolerances of +/- 0.0002 and feature micro-channels and anatomical shapes not otherwise possible with traditional manufacturing. With 3D printing, dental implants can be as complex as needed without the hefty price tag.

i3D MFG owns EOS M280, M290 and M400 x4 DMLS/DMLM 3D printing machines. Our state-of-the-art equipment enables us to achieve densities at nearly 100%. We have access to full parameter sets for our machines and are the first to adopt all upgrades and improvements to ensure excellence in DMLS/DMLM production quality. Lattice and honeycomb designs can be utilized to provide optimal osteoconductive behavior and minimal implant rejection.

Medical Device

3D printed medical implants do away with traditional design-for-manufacture constraints. Organic shapes, anatomically-driven design, micro-channels, conformal channels, and micro-parts are all cost-effective and possible with 3D metal manufacturing. With printed held tolerances of +/- 0.002, precision is assured at more affordable prices than traditional machining or casts.

Surgical Implants & Devices                                     

DMLS/DMLM can amass multiple customized files on a single build plate without expensive tooling or set-up costs. With printed tolerances of +/- 0.0002 and the ability to print micro-channels and anatomical shapes, 3D printing revolutionizes the cost-effective production of complex, custom medical implants and specialized surgical devices that are otherwise too costly or physically impossible to traditionally manufacture.

DMLM/DMLS erases traditional design-for-manufacture constraints. 3D models drive the printer to fuse micro-layers of medical grade titanium or stainless steel together in 20 to 40-micron layers until thousands of fused layers create a fully functional production part. With densities approaching 100%, any traditional post-process finish is possible.

Metals We Print

i3D MFG offers an extensive selection of DMLS standard metal powders, including titanium, Inconel, and custom metal powder applications. Our engineers provide our customers with significant competitive advantages in design and proprietary advancements.

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Aluminum (Al)

AlSi10 is ideal for use in projects that require excellent thermal and low weight considerations. It is an optimal metal for parts that feature thin walls and complex geometries.

Titanium (Ti)

Ti64 is well suited for medical, aerospace, firearms, energy and automotive projects that require corrosion resistance, strength, weight reduction, and biocompatibility.

Stainless Steels

PH1 is a medical grade, serializable, and corrosion-resistant steel that is typically 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.

Maraging Steel

Maraging steel powder has excellent strength and mechanical properties. MS1 is a pre-alloyed, ultra-high strength steel powder with a chemical composition corresponding 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 DMLS/DMLM nickel alloys. These alloys feature superior heat resistance and ytpical heat treatment hardnesses 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/DMLM powder development. As a North American EOS Material Process Application (MPA) Development Partner, we have access to the latest DMLS/DMLM machine parameter sets, enabling i3D™ to develop customized powder applications for aerospace, rocket, defense, firearms, oil & gas, energy, automotive, recreational, and casting customers.

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