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Direct Metal Laser Solidification (DMLS®) 3D Printing for the Medical Device Industry

i3DMFG 3D Printing For Medical Industry

3D printing using DMLS® 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. 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 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.

i3DMFG™ owns EOS M280, M290 and M400.4 DMLS® 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® 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® 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.

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 60-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

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.

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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, 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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