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3D Printing Services For The Tooling Industry

i3DMFG 3D Printing Tooling Industry

Direct Metal Laser Solidification (DMLS®) is a 3D printing process that revolutionizes mold tool design and production. 3D CAD models drive the machine to fuse micro-layers of powder together using 400W lasers on 20 to 60 micron layers of metal powder, creating a nearly 100% dense, fully functional production mold tool. DMLS® can “print” conformal cooling lines, lattice geometries, and complex core/cavity designs that are too costly or simply impossible to traditionally manufacture. This opens up unlimited options for engineers to incorporate internal channels, curved features, cooling and heating efficiencies, varied layers throughout a single mold, and flexible interchangeable mold designs.

i3DMFG™ can print mold core/cavities in days, giving end-use customers competitive advantages in time-to-market, product development, and small batch production. Our aluminum and tool steel, and stainless steel mold tools can be post-processed in all of the same ways as cast or machined parts, from polishing to welding to anodization.

Horizontal Injection Mold Tools

DMLS® eliminates traditional design-for-manufacture constraints because 3D models drive 400W lasers to fuse micro-layers of powder together in linear and organic shapes. Since the DMLS® part is grown layer by layer, in tens of thousands of layers, complex internal geometries, conformal cooling channels, micro-channels, latticed and honeycombed designs, and free-form shapes are all easily manufacturable. Conformal cooling channels greatly improve part production efficiencies and allow designers to incorporate varied wall thicknesses and part improvements that were confined by traditional mold tool linear cooling line limitations.

DMLS® produces final production quality mold cores and cavities that can be finished just like machined or cast parts. With i3DMFG™’s DMLS® production, injection molders can now offer their clients tool design, manufacture, and part production in as little as 3 weeks. The process is all on-shore, protecting customer designs and costly tool change time and shipping.

Vertical Injection Mold Tools

DMLS® in aluminum and tool steel allows i3DMFG™ to 3D print Morgan Press mold blocks in days and post process to any finish requirements for up to 30% less than CNC molds. Typically, the more complex the cavity requirements, the more economical the DMLS® process will be. With densities approaching 100%, any traditional post-process finish is possible. Printed held tolerances up to +/- 0.002 enable precise design manufacturing with the option to add material and post process to even tighter tolerances but from a much closer starting point than typically seen in traditional machine or cast parts, thereby reducing costly hand-finish costs. The process is all on-shore, protecting customer designs and costly tool change time and shipping.

Interchangeable Core/Cavity Blocks                         

i3DMFG™ utilizies EOS M280, M290 and M400.4 DMLS® machines. As an official Material Process Applications (MPA) for EOS, i3DMFG™ prides itself on its DMLS® material and 3D print application innovations. Our interchangeable mold tool core/cavity universal base provides injection molders flexibility in switching out core/cavities in small and medium batch runs at economical tooling and change-over costs.

With the latest, highest quality equipment i3DMFG™ is able to achieve densities at nearly 100%, allowing for any finish requirements to the various 3D printed core/cavities. Lattice and honeycomb designs specially tailored for optimal part cooling and heating add more value to the mold block design options. Injection molders can offer their clients tool design, manufacture, and part production in as little as 3 weeks. The process is all on-shore, protecting customer designs and costly tool change time and shipping.

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.

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

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