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Proto Labs, Inc.
5540 Pioneer Creek Dr.
Maple Plain, MN 55359
United StatesP: 877.479.3680
F: 763.479.2679
E: [email protected]Best-in-Class Online Quoting
After uploading your part design, you'll receive an online quote that includes manufacturing analysis to help improve part manufacturability. Within your quote, you can also adjust quantity and material and see price changes in real-time.
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Jump to Section→ Capabilities
→ Available Alloys
→ Compare Material Properties
→ Surface Finishes
→ Post-Processing
→ Why Metal 3D Printing?
Direct metal laser sintering (DMLS) is an industrial metal 3D printing process that builds fully functional metal prototypes and production parts in 7 days or less.
A range of metals produce final parts that can be used for end-use applications.
Metal 3D printing technology is commonly used for:
- Prototyping in production-grade materials
- Complex geometries
- Functional, end-use parts
- Reducing metal components in an assembly
We hope you find this guide helpful. If the file did not download, you can find it here.
Metal 3D Printing Guide
Jump start your metal 3D printing with this guide that covers material selection, design, post-processing, and quality inspections.
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Metal 3D Printing Capabilities
Our basic guidelines for metal 3D printing include important design considerations to help improve part manufacturability, enhance cosmetic appearance, and reduce overall production time.
Metal 3D Printing Tolerances
For well-designed parts, tolerances of +0.003 in. (0.076mm) plus 0.1% of nominal length can typically be achieved. Note that tolerances may change depending on part geometry.
Max Dimensions
Layer Thickness
Minimum Feature Size
Tolerances
*At this time, Inconel 718 and Aluminum are the only materials available on our large format, X Line machine
Metal 3D Printing Material Options
Below is our available metal alloys for 3D printing.
Various heat treatments are available depending on material.
Stainless Steel (17-4 PH)
Stainless Steel 17-4 PH is a precipitation hardened stainless steel that is known for its hardness and corrosion resistance. If needing a stainless steel option, select 17-4 PH for its significantly higher tensile strength and yield strength, but recognize that it has far less elongation at break than 316L. Final parts built 17-4 PH receive vacuum solution heat treatment as well as H900 aging.
Primary Benefits
- Heat treated for full hardness and strength
- Corrosion resistance
LEARN MORE>
Stainless Steel (316L)
Stainless steel 316L is a workhorse material used for manufacturing acid and corrosion resistant parts. Select 316L when stainless steel flexibility is needed; 316L is a more malleable material compared to 17-4 PH. Final parts built in 316L receive stress relief application.
Primary Benefits
- Acid and corrosion resistance
- High ductility
LEARN MORE>
Aluminum (AlSi10Mg)
Aluminum (AlSi10Mg) is comparable to a 3000 series alloy that is used in casting and die casting processes.
It has good strength -to-weight ratio, high temperature and corrosion resistance, and good fatigue, creep and rupture strength. AlSi10Mg also exhibits thermal and electrical conductivity properties. Final parts built in AlSi10Mg receive stress relief application.
Primary Benefits
- High stiffness and strength relative to weight
- Thermal and electrical conductivity
LEARN MORE>
Inconel 718
Inconel is a high strength, corrosion resistant nickel chromium superalloy ideal for parts that will experience extreme temperatures and mechanical loading. Final parts built in Inconel 718 receive stress relief application. Solution and aging per AMS 5663 is also available to increase tensile strength and hardness.
Primary Benefits
- Oxidation and corrosion resistance
- High performance tensile, fatigue, creep, and rupture strength
LEARN MORE>
Cobalt Chrome (Co28Cr6Mo)
Cobalt Chrome (Co28Cr6Mo) is a superalloy is known for its high strength-to-weight ratio.
Primary Benefits
- High performance tensile and creep
- Corrosion resistance
LEARN MORE>
Titanium (Ti6Al4V)
Titanium (Ti6Al4V) is a workhorse alloy. Versus Ti grade 23 annealed, the mechanical properties of Ti6Al4V are comparable to wrought titanium for tensile strength, elongation, and hardness. Final parts built in Ti6Al4V receive vacuum stress relief application.
Primary Benefits
- High stiffness and strength relative to weight
- High temperature and corrosion resistance
LEARN MORE>
Compare Material Properties
20 μm = high resolution (HR)
30, 40, and 60 μm = normal resolution (NR)
- US
- Metric
| Materials | Resolution | Condition | Ultimate Tensile Strength (ksi) | Yield Stress (ksi) | Elongation (%) | Hardness |
|---|---|---|---|---|---|---|
| Stainless Steel (17-4 PH) | 20 μm | Solution & Aged (H900) | 199 | 178 | 10 | 42 HRC |
| 30 μm | Solution & Aged (H900) | 198 | 179 | 13 | 42 HRC | |
| Stainless Steel (316L) | 20 μm | Stress Relieved | 82 | 56 | 78 | 90 HRB |
| 30 μm | Stress Relieved | 85 | 55 | 75 | 88 HRB | |
| Aluminum (AlSi10Mg) | 20 μm | Stress Relieved | 39 | 26 | 15 | 42 HRB |
| 30 μm | Stress Relieved | 50 | 33 | 8 | 59 HRB | |
| 40 μm | Stress Relieved | 43 | 27 | 10 | 50 HRB | |
| Cobalt Chrome (Co28Cr6Mo) | 20 μm | As Built | 182 | 112 | 17 | 39 HRC |
| 30 μm | As Built | 176 | 119 | 14 | 38 HRC | |
| Inconel 718 | 20 μm | Stress Relieved | 143 | 98 | 36 | 33 HRC |
| 30 μm | Stress Relieved | 144 | 91 | 39 | 30 HRC | |
| 30 μm | Solution & Aged per AMS 5663 | 208 | 175 | 18 | 46 HRC | |
| 60 μm | Stress Relieved | 139 | 83 | 40 | 27 HRC | |
| 60 μm | Solution & Aged per AMS 5663 | 201 | 174 | 19 | 45 HRC | |
| Titanium (Ti6Al4V) | 20 μm | Stress Relieved | 153 | 138 | 15 | 35 HRC |
| 30 μm | Stress Relieved | 144 | 124 | 18 | 33 HRC |
| Materials | Resolution | Condition | Ultimate Tensile Strength (MPa) | Yield Stress (MPa) | Elongation (%) | Hardness |
|---|---|---|---|---|---|---|
| Stainless Steel (17-4 PH) | 20 μm | Solution & Aged (H900) | 1,372 | 1,227 | 10 | 42 HRC |
| 30 μm | Solution & Aged (H900) | 1,365 | 1,234 | 13 | 42 HRC | |
| Stainless Steel (316L) | 20 μm | Stress Relieved | 565 | 386 | 78 | 90 HRB |
| 30 μm | Stress Relieved | 586 | 379 | 75 | 88 HRB | |
| Aluminum (AlSi10Mg) | 20 μm | Stress Relieved | 268 | 180 | 15 | 46 HRB |
| 30 μm | Stress Relieved | 345 | 228 | 8 | 59 HRB | |
| 40 μm | Stress Relieved | 296 | 186 | 10 | 50 HRB | |
| Cobalt Chrome (Co28Cr6Mo) | 20 μm | As Built | 1255 | 772 | 17 | 39 HRC |
| 30 μm | As Built | 1213 | 820 | 14 | 38 HRC | |
| Copper (CuNi2SiCr) | 20 μm | Precipitation Hardened | 496 | 434 | 23 | 87 HRB |
| Inconel 718 | 20 μm | Stress Relieved | 986 | 676 | 36 | 33 HRC |
| 30 μm | Stress Relieved | 993 | 627 | 39 | 30 HRC | |
| 30 μm | Solution & Aged per AMS 5663 | 1434 | 1207 | 18 | 46 HRC | |
| 60 μm | Stress Relieved | 958 | 572 | 40 | 27 HRC | |
| 60 μm | Solution & Aged per AMS 5663 | 1386 | 1200 | 19 | 45 HRC | |
| Titanium (Ti6Al4V) | 20 μm | Stress Relieved | 1055 | 951 | 15 | 35 HRC |
| 30 μm | Stress Relieved | 993 | 855 | 18 | 33 HRC |
These figures are approximate and dependent on a number of factors, including but not limited to, machine and process parameters. The information provided is therefore not binding and not deemed to be certified. When performance is critical, also consider independent lab testing of additive materials or final parts.
Surface Finish Options
Standard Finish
Expect roughness values of 200 to 400 µin Ra (0.005 to 0.010mm Ra), depending on material and resolution. Support structures are removed and layer lines are visible.
Custom Finish
We offer brushed surfaces in a range of grits and polished mirror finishes. Be sure to indicate if the custom surface finish is for functional or aesthetic purposes so we can best consult you on our custom options.
Post-Processing Capabilities for Metal 3D-Printed Parts
Improve strength, dimensional accuracy, and cosmetic appearance of final metal components with DMLS for production.
Surface Finishing
- 3- and 5-axis milling
- Turning
- Polish (Mirror or Brushed)
- Passivation
- Wire EDM
- Tapping and reaming
Heat Treatments
- Stress relief
- NADCAP heat treatment
- Hot isostatic pressing (HIP)
- Solution annealing
- Aging
Mechanical Testing
- Tensile
- Rockwell Hardness
Powder Analysis & Material
- Traceability
- Chemistry
- Particle size and distribution analysis
Why Use Metal 3D Printing?
See how metal additive manufacturing technology can be used to reduce components within an assembly, fabricate complex geometries, and ultimately save you time and costs.
Click to enlarge
How Does Metal 3D Printing Work?
The DMLS machine begins sintering each layer—first the support structures to the base plate, then the part itself—with a laser aimed onto a bed of metallic powder. After a cross-section layer of powder is micro-welded, the build platform shifts down and a recoater blade moves across the platform to deposit the next layer of powder into an inert build chamber. The process is repeated layer by layer until the build is complete.
When the build finishes, an initial brushing is manually administered to parts to remove a majority of loose powder, followed by the appropriate heat-treat cycle while still fixtured in the support systems to relieve any stresses. Parts are removed from the platform and support structures are removed from the parts, then finished with any needed bead blasting and deburring. Final DMLS parts are near 100 percent dense.
Large Format Metal 3D Printing
We recently added the GE Additive X Line to our fleet of metal 3D printers to build large Inconel 718 and Aluminum (AlSi10Mg) parts. Have a project that might be a good fit? Contact us and we can discuss your requirements.
Learn More >
Metal 3D Printing for Production
Improve strength, dimensional accuracy, and cosmetic appearance for end-use metal components with post-processing options like CNC machining and heat treatments.
Learn More >
Resources
Design Tip
Post-Processing for Metal 3D Printing
Learn how to improve dimensional accuracy, surface roughness, and mechanical properties on metal parts with high-requirement applications.
Read Design Tip
White Paper
Combining Part Assemblies with Additive Manufacturing to Reduce Cost and Increase Performance
How to find the right opportunities to consolidate multi-part assemblies into single components with industrial 3D printing
Read White Paper
Blog
Inconel 718: A Workhorse Material for Additive Manufacturing
Inconel 718 is a go-to material for additive manufacturing of metal parts.
Read Blog
Blog
Large Format 3D Printing for Aluminum and Inconel Parts
When you’re printing really large parts in metal, it’s great to have a choice of materials. Aluminum and Inconel 718 both make a lot of sense, but which one is the best for your application?
Read Blog
Instant quotes on 3D-printed parts
Get A QuoteDirect Metal Laser Sintering (DMLS)
CapabilitiesCustom Online 3D Printing ServiceDirect Metal Laser Sintering (DMLS) 3D Printing Service
Upload your CAD files to get an instant quote on metal prototypes and production parts. Free shipping on all US orders.
CapabilitiesHow It WorksMaterialsFinishesApplications and BenefitsDownload GuideDMLS Produces High-Quality Metal Parts Without Tooling
Direct metal laser sintering (DMLS) is a metal 3D printing technology used to build metal parts with exceptional mechanical properties and precision. Our Manufacturing Supplier Network gives you massive on-demand production capacity with a wide range of DMLS machines and high-performance materials.
Designers often chose DMLS for its ability to produce all-in-one metal assemblies and highly precise metal parts with complex features like internal supports and lattices. DMLS does not have upfront setup or tooling costs, making it an affordable option for fully dense metal parts, with the design freedom of additive manufacturing. With DMLS’s affordability, speed, and superior design freedoms, companies and creators can build metal designs they never thought possible and produce accurate metal components.
Use the 3D viewer above to preview Xometry’s part rendering features.
Xometry Direct Metal Laser Sintering 3D Printing Service Capabilities
| Feature | Description |
|---|---|
Feature Build Size | Description 10" x 10" x 10" (250 x 250 x 250 mm) |
Feature General Tolerances | Description +/- 0. |
Feature Layer Height | Description .0012” - .0016" depending on material |
Feature Surface Roughness | Description 150-400 µin Ra, depending on build orientation and material used for the build |
Feature Infill | Description 100% |
This table depicts the general tolerances for Direct Metal Laser Sintering (DMLS). Stresses during the build and other geometry considerations may cause deviation in tolerances and flatness. Part designs with thicker geometries, flat or broad parts, and parts with uneven wall thicknesses may be prone to significant deviations or warp. Improved tolerances may be possible with a manual quote review, after successful completion of a prototype build, and must be approved on a case-by-case basis. General tolerances apply before secondary finishing or post-processing unless otherwise specified. Please check out Xometry's Manufacturing Standards for more information on tolerances per process.
How a Direct Metal Laser Sintering Machine Works
Direct metal laser sintering (DMLS) is an additive metal printing technology that builds metal parts from a CAD file by selectively fusing stainless steel or aluminum powder into thin layers.
Direct metal laser sintering’s layer-by-layer printing allows multiple parts to be combined during the printing process. With traditional manufacturing processes, metal parts are machined or metal casted into several parts and assembled. Printing an all-in-one assembly strengthens the finished part while reducing the weight and cost of production significantly. DMLS techniques can also create parts at a high density. This is ideal for parts under high pressure such as in oil and gas industries.
Direct Metal 3D Printing Materials
DMLS Materials Available at Xometry:
| Material Name | Description | Data Sheets |
|---|---|---|
Material Name 3D Printed Aluminum AlSi10Mg | Description Lightweight aluminum alloy. | Data Sheets AlSi10Mg Data Sheet |
Material Name 3D Printed Stainless Steel 17-4 | Description Fully-Dense 17-4 PH stainless steel metal, hardness 40 HRC, heat treatable. | Data Sheets SS 17-4 Data Sheet |
Material Name 3D Printed Stainless Steel 316/L | Description Fully-dense 316L stainless steel metal, superb corrosion resistance, meets requirements of ASTM F138. | Data Sheets SS 316/L Data Sheet |
Additional materials are available upon request! Review more information about our materials here.
Available Finishes
Standard: In addition to the removal of support structures, the part surface is media blasted to provide a uniform finish.
Custom: Additional DMLS post-processing, such as CNC Machining of features and polishing, are evaluated on a case-by-case basis and can be requested in the quoting tool.
Best Applications for DMLS
Rapid Tooling
Because DMLS parts are strong yet lightweight, they are widely used for rapid tooling, fixtures, and jigs.
Rapid Prototyping
DMLS metal laser printing is typically affordable and fast, and therefore is often used to make proof-of-concept models and fully functional late-stage prototypes.
Production
Cast-quality finish (fully dense) and durable materials make DMLS printing a favorite technology for end-use products.
Ready to get started on your 3D printing quote?
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Why Choose Xometry for DMLS 3D Printing?
Endless Options
Choose from thousands of possible combinations of materials, finishes, tolerances, markings, and certifications for your order.
Easy to Use
Get your parts delivered right to your door without the hassle of sourcing, project management, logistics, or shipping.
Vetted Network
We are ISO 9001:2015, ISO 13485, and AS9100D certified. Only the top shops that apply to become Suppliers make it through our qualification process.
Download the DMLS Design Guide
How metal 3D printers work. Overview of SLM and DMLS technologies. additive manufacturing. 3D metal printing.
Metal 3D printing. Additive technologies.
SLM or DMLS: what's the difference?
Hello everyone, Friends! 3DTool is with you!
BLT metal 3D printer catalog
Selective laser melting ( SLM ) and direct metal laser sintering ( DMLS ) are two additive manufacturing processes that belong to the family of 3D printing using the powder layer method. The two technologies have much in common: they both use a laser to selectively melt (or melt) metal powder particles, bonding them together and creating a pattern layer by layer. In addition, the materials used in both processes are metals in granular form.
The differences between SLM and DMLS come down to the basics of the particle bonding process: SLM uses metal powders with a single melting point and completely melts the particles, while in DMLS the powder consists of materials with variable melting points.
Specifically:
SLM produces single metal parts while DMLS produces metal alloy parts.
Both SLM and DMLS technologies are used in industry to create final engineering products. In this article, we will use the term "metal 3D printing" to summarize the 2 technologies. We will also describe the main mechanisms of the manufacturing process that are necessary for engineers to understand the advantages and disadvantages of these technologies.
There are other manufacturing processes for producing dense metal parts, such as electron beam melting (EBM) and ultrasonic additive manufacturing (UAM). Their availability and distribution is rather limited, so they will not be presented in this article.
How 3D printing with SLM or DMLS metal works.
How does metal 3D printing work? The basic manufacturing process for SLM and DMLS is very similar.
1. The printing chamber is first filled with an inert gas (such as argon) to minimize the oxidation of the metal powder. It then heats up to the optimum operating temperature.
2. A layer of powder is spread over the platform, a powerful laser makes passes along a predetermined path in the program, fusing the metal particles together and creating the next layer.
3. When the sintering process is completed, the platform moves down 1 layer. Next, another thin layer of metal powder is applied. The process is repeated until the entire model is printed.
When the printing process is completed, the metal powder already has strong bonds in the structure. Unlike the SLS process, parts are attached to the platform via support structures. The support in metal 3D printing is created from the same material as the base part. This condition is necessary to reduce deformations that may occur due to high processing temperatures.
When the 3D printer's chamber cools down to room temperature, excess powder is removed manually, such as with a brush. The parts are then typically heat treated while they are still attached to the platform. This is done to relieve any residual stresses. They can then be further processed. The removal of the part from the platform occurs by means of sawing.
Scheme of operation of a 3D printer for metal.
In SLM and DMLS, almost all process parameters are set by the manufacturer. The layer height used in metal 3D printing varies from 20 to 50 microns and depends on the properties of the metal powder (fluidity, particle size distribution, shape, etc. ).
The basic size of the print area on metal 3D printers is 200 x 150 x 150 mm, but there are also larger sizes of the working area. Printing accuracy is from 50 - 100 microns. As of 2020, metal 3D printers start at $150,000. For example, our company offers 3D metal printers from BLT.
metal 3D printers can be used for small batch production, but the 3D printing capabilities of such systems are more like those of mass production on FDM or SLA machines.
The metal powder in SLM and DMLS is recyclable: typically less than 5% is consumed. After each impression, the unused powder is collected and sieved, and then topped up with fresh material to the level required for the next production.
Waste in metal printing, are supports (support structures, without which it will not be possible to achieve a successful result). With too much support on the manufactured parts, the cost of the entire production will increase accordingly.
Adhesion between coats.
3D metal printing on BLT 3D printers
SLM and DMLS metal parts have almost isotropic mechanical and thermal properties. They are hard and have very little internal porosity (less than 0.2% in 3D printed condition and virtually non-existent after processing).
Metal printed parts have higher strength and hardness and are often more flexible than traditionally made parts. However, such metal becomes “tired” faster.
3D model support structure and part orientation on the work platform.
Support structures are always required when printing with metal, due to the very high processing temperatures. They are usually built using a lattice pattern.
Supports in metal 3D printing perform 3 functions:
• They form the basis for creating the first layer of the part.
• They secure the part to the platform and prevent it from deforming.
• They act as a heat sink, removing heat from the model.
Parts are often oriented at an angle. However, this will increase the amount of support required, the printing time, and ultimately the overall cost.
Deformation can also be minimized with laser sintering templates. This strategy prevents the accumulation of residual stresses in any particular direction and adds a characteristic surface texture to the part.
Since the cost of metal printing is very high, software simulations are often used to predict how a part will behave during processing. These topology optimization algorithms are otherwise used not only to increase mechanical performance and create lightweight parts, but also to minimize the need for supports and the likelihood of part distortion.
Hollow sections and lightweight structures.
An example of printing on a BLT 3D printer
Unlike polymer powder melt processes such as SLS, large hollow sections are not typically used in metal printing as the support would be very difficult to remove, if at all possible.
For internal channels larger than Ø 8 mm, it is recommended to use diamond or teardrop cross-sections instead of round ones, as they do not require support. More detailed recommendations on the design of SLM and DMLS can be found in other articles on this topic.
As an alternative to hollow sections, parts can be made with sheath and cores, which in turn are machined using different laser power and pass speeds, resulting in different material properties. The use of sheath and cores is very useful when making parts with a large solid section, as it greatly reduces printing time and reduces the chance of warping.
The use of a lattice structure is a common strategy in metal 3D printing to reduce part weight. Topology optimization algorithms can also help design organic lightweight shapes.
Consumables for 3D metal printing.
SLM and DMLS technologies can produce parts from a wide range of metals and metal alloys, including aluminum, stainless steel, titanium, cobalt, chromium and inconel. These materials meet the needs of most industrial applications, from aerospace to medical applications. Precious metals such as gold, platinum, palladium and silver can also be processed, but their use is of a minor nature and is mainly limited to jewelry making.
The cost of metal powder is very high. For example, a kilogram of 316 stainless steel powder costs approximately $350-$450. For this reason, minimizing part volume and the need for supports is key to maintaining optimal manufacturing cost.
The main advantage of metal 3D printing is its compatibility with high-strength materials such as nickel or cobalt-chromium superalloys, which are very difficult to machine with traditional methods. Significant cost and time savings can be achieved by using metal 3D printing to create a near-clean shape part. Subsequently, such a part can be processed to a very high surface quality.
Metal post-processing.
Various post methods. treatments are used to improve the mechanical properties, accuracy and appearance of metal printed products.
Mandatory post-processing steps include the removal of loose powder and support structures, while heat treatment (heat annealing) is typically used to relieve residual stresses and improve the mechanical properties of the part.
CNC machining can be used for critical features (such as holes or threads). Sandblasting, plating, polishing, and micro-machining can improve the surface quality and fatigue strength of a metal printed part.
Advantages and disadvantages of metal 3D printing.
Pros:
1. Metal 3D printing can be used to make complex custom parts, with geometries that traditional manufacturing methods cannot provide.
2. Metal 3D printed parts can be optimized to increase their performance with minimal weight.
3. Metal 3D printed parts have excellent physical properties, metal 3D printers can print a wide range of metals and alloys. Includes difficult-to-machine materials and metal superalloys.
Cons:
1. Manufacturing costs associated with metal 3D printing are high. The cost of consumables is from $ 500 per 1 kg.
2. The size of the working area in metal 3D printers is limited.
Conclusions.
• Metal 3D printing is most suitable for complex, one-piece parts that are difficult or very expensive to manufacture using traditional methods, such as CNC.
• Reducing the need for building supports, will significantly reduce the cost of printing with metal.
• 3D printed metal parts have excellent mechanical properties and can be made from a wide range of engineering materials, including superalloys.
And that's all we have! We hope the article was useful to you.
Catalog of 3D printers for metal BLT
You can purchase metal 3d printers, as well as any other 3d printers and CNC machines, by contacting us:
• By email: Sales@3dtool. ru
• By phone: 8(800)775-86-69
• Or on our website: http://3dtool.ru
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Metal 3D printing
Metal 3D printing can be considered one of the most enticing and technologically challenging areas of additive manufacturing. Attempts to print with metals have been made since the early days of 3D printing technologies, but in most cases they ran into technological incompatibilities. In this section, we will look at technologies that have been tested for printing both composite materials containing metals and pure metals and alloys.
- 1 3D inkjet printing (3DP)
- 2 Lamination Printing (LOM)
- 3 Layered deposition (FDM/FFF)
- 4 Selective Laser Sintering (SLS) and Direct Metal Sintering (DMLS)
- 5 Selective laser (SLM) and electron beam melting (EBM)
- 6 Direct laser additive construction (CLAD)
- 7 Random electron beam melting (EBFȝ)
3D inkjet printing (3DP)
How 3D inkjet printers (3DP) work
Inkjet 3D printing is not only one of the oldest additive manufacturing methods, but also one of the most successful in terms of using metals as consumables . However, it is necessary to immediately clarify that this technology allows you to create only composite models due to the technological features of the process. In fact, this method allows you to create three-dimensional models from any materials that can be processed into powder. The binding of the powder is carried out using polymers. Thus, finished models cannot be called fully "metal".
At the same time, it is possible to transform composite models into all-metal ones due to heat treatment to melt or burn out the binder material and sinter the metal particles. The models obtained in this way do not have high strength due to porosity. An increase in strength is possible due to the impregnation of the resulting all-metal model. For example, it is possible to impregnate a steel model with bronze to obtain a stronger structure.
Models obtained in this way, even with metal impregnation, are not used as mechanical components due to their relatively low strength, but are actively used in the jewelry and souvenir industry.
Lamination printing (LOM)
How 3D printers using lamination technology (LOM) work
models.
Metallic foil can also be used as a consumable.
The resulting models are not all metal, as their integrity is based on the adhesive used to bond the consumable sheets.
The advantage of this technology is the relative cheapness of production and the high visual similarity of the resulting models with all-metal products. Typically, this method is used for layout.
FDM/FFF
Model made with BronzeFill before and after polishing
The most popular 3D printing method has also not bypassed the use of metals as consumables. Unfortunately, attempts to print with pure metals and alloys have so far not led to significant success. The use of refractory metals runs into quite predictable problems with the choice of materials for the construction of extruders, which, by definition, must withstand even higher temperatures.
Printing with fusible alloys (for example, tin) is possible, but does not give enough high-quality output for practical use.
Thus, in recent years, the attention of consumables developers has switched to composite materials, similar to inkjet printing. A typical example is BronzeFill, a composite material consisting of thermoplastic (details not disclosed, but apparently PLA plastic is used) and bronze powder. The resulting models have a high visual similarity with natural bronze and can even be polished to a high gloss. Unfortunately, the physical and chemical properties of finished products are limited by the parameters of the thermoplastic binder, which does not allow classifying such models as all-metal.
Nevertheless, such materials can be used not only in the creation of models, souvenirs and art objects, but also in industry. Thus, the experiments of enthusiasts have shown the possibility of creating conductors and shielding materials using thermoplastics with a metal filler. The development of this direction can make it possible to print electronic circuit boards.
Selective Laser Sintering (SLS) and Direct Metal Sintering (DMLS)
The most common method for creating all-metal 3D models involves the use of laser machines for sintering metal powder particles. This technology is referred to as Selective Laser Sintering or SLS. It should be noted that SLS is used not only for working with metals, but also with thermoplastics in powder form. In addition, metallic materials are often coated with more fusible materials to reduce the required power of laser emitters. In such cases, finished metal models require additional sintering in furnaces and impregnation to increase strength.
A variation of the SLS technology is Direct Metal Laser Sintering (DMLS), which, as the name implies, is focused on working with pure metal powders. These plants are often equipped with sealed working chambers filled with an inert gas for working with metals subject to oxidation, such as titanium. In addition, DMLS printers necessarily apply consumable heating to a point just below the melting point, which saves on the power of laser systems and speeds up the printing process.
SLS, DLMS and SLM systems
The laser sintering process starts with the application of a thin layer of heated powder onto the work platform. The thickness of the applied layers corresponds to the thickness of one layer of the digital model. Then the particles are sintered between themselves and with the previous layer. Changing the trajectory of the laser beam is carried out using an electromechanical system of mirrors.
When a layer is drawn, the excess material is not removed, but serves as a support for subsequent layers, which allows you to create complex shapes, including hanging elements, without the need to build additional support structures. This approach, coupled with high accuracy and resolution, makes it possible to obtain parts that require almost no machining, as well as solid parts of a level of geometric complexity that is unattainable by traditional production methods, including casting.
Laser sintering allows you to work with a wide range of metals, including steel, titanium, nickel alloys, precious materials, etc. The only drawback of the technology can be considered the porosity of the resulting models, which limits the mechanical properties and does not allow achieving strength at the level of cast counterparts.
Selective Laser (SLM) and Electron Beam Melting (EBM)
Despite the high quality of the patterns produced by laser sintering, their practical application is limited by the relatively low strength due to porosity. Such products can be used for rapid prototyping, prototyping, jewelry production and many other tasks, but are of little use for the production of parts that can withstand high loads. One solution to this problem has been the conversion of direct metal laser sintering (DMLS) technology to laser melting additive manufacturing (SLM) technology. In fact, the only fundamental difference between these methods is the degree of heat treatment of the metal powder: SLM technology is based on complete melting to obtain homogeneous models that are practically indistinguishable in physical and mechanical properties from cast counterparts.
An example of a titanium implant made using electron beam melting (EBM) technology
A parallel method that has achieved excellent results is electron beam melting (EBM). At the moment, there is only one manufacturer that creates EBM printers - the Swedish company Arcam.
EBM achieves precision and resolution comparable to laser melting, but with some advantages. Thus, the use of electron guns makes it possible to get rid of the delicate electromechanical mirror systems used in laser systems. In addition, the manipulation of electron beams using electromagnetic fields is possible at speeds that are incomparably higher compared to electromechanical systems, which, coupled with an increase in power, makes it possible to achieve increased productivity without significantly complicating the design. Otherwise, the design of SLM and EBM printers is similar to laser metal sintering machines.
The ability to work with a wide range of metals and alloys allows you to create small batches of specialized metal parts that are almost as good as samples obtained using traditional production methods. There is no need to create additional tools and infrastructure, such as molds and furnaces. Accordingly, significant savings are possible in prototyping or small-scale production.
Laser and electron beam melting machines have been successfully used to produce items such as orthopedic titanium prostheses, gas turbine blades and jet engine injectors, among others.
Direct Laser Additive Building (CLAD)
How CLAD plants work
Not so much a 3D printing technology as a "3D repair" technology. The technology is used exclusively at the industrial level due to the complexity and relatively narrow specialization.
CLAD is based on the deposition of metal powder on damaged parts, followed by immediate welding with a laser. The positioning of the "print head" is carried out along five axes: in addition to moving in three planes, the head has the ability to change the angle of inclination and rotate around the vertical axis, which allows you to work at any angle.
Such devices are often used to repair large items, including manufacturing defects. For example, the installations of the French company BeAM are used to repair aircraft engines and other complex mechanisms.
Complete CLAD units use a sealed inert atmosphere working chamber for titanium and other oxidizable metals and alloys.
Free electron beam melting (EBFȝ)
How EBF printers work
Technology developed by NASA for use in zero gravity. Since the absence of gravity makes working with metal powders almost impossible, EBFȝ technology involves the use of metal threads.
The build process is similar to Fused Deposition 3D printing (FDM), but using an electron beam gun to fuse the consumable.
This technology will allow the creation of metal spare parts in orbit, which will significantly reduce the cost of delivering parts and provide the ability to quickly respond to emergency situations.
