Direct metal laser sintering:

Direct metal laser sintering (DMLS) is an additive metal fabrication technology developed by EOS out of Munich, Germany, somtimes also referred to by the terms Selective Laser Sintering (SLS) orSelective Laser Melting (SLM). The process involves use of a 3D CAD model whereby a .stl file is created and sent to the machines software. A technician works with this 3D model to properly orient the geometry for part building and adds supports structure as appropriate. Once this build file has been completed, it is sliced into the layer thickness the machine will build in and downloaded to the DMLS machine allowing the build to begin. The DMLS machine uses a high-powered 200 Watt Yb-fiber optic laser. Inside the build chamber area, there is a material dispensing platform and a build platform along with a recoater blade used to move new powder over the build platform. The technology fuses metal powder into a solid part by melting it locally using the focused laser beam. Parts are built up additively layer by layer, typically using 20 micron layers. This process allows for highly complex geometries to be created directly from the 3D CAD data, fully automatically, in hours and without anytooling. DMLS is a net-shape process, producing parts with high accuracy and detail resolution, good surface quality and excellent mechanical properties.

Benefits:
DMLS has many benefits over traditional manufacturing techniques. Speed is the most obvious because no special tooling is required and parts can be built in a matter of hours. Additionally, DMLS allows for more rigorous testing of prototypes. Since DMLS can use most alloys, prototypes can now be functional hardware made out of the same material as production components. The advantages do not stop with prototyping; DMLS is one of the few additive manufacturing technologies being used in production. It allows more design freedom, and more efficient designs in technical applications. Since the components are built layer by layer, it is possible to design internal features and passages that could not be cast or otherwise machined. Complex geometries and assemblies with multiple components can be simplified to fewer parts with a more cost effective assembly. DMLS does not require special tooling like castings, so production runs can be shorter and supply chains can carry less inventory.

Applications:
This technology is used to manufacture direct parts for a variety of industries including aerospace, dental, medical and other industries that have small to medium size, highly complex parts and the tooling industry to make direct tooling inserts. With a build envelop of 250mm x 250mm x 185mm height, and the ability to grow multiple parts at one time, DMLS is a very cost and time effective technology. The technology is used both for rapid prototyping, as it decreases development time for new products, and production manufacturing as a cost saving method to simplify assemblies and complex geometries.

Constraints:
The aspects of size, feature details and surface finish, as well as print through error in the Z axis may be factors that should be considered prior to the use of the technology. However, by planning the build in the machine where most features are built in the x and y axis as the material is laid down, the feature tolerances can be managed well. Do note that surfaces usually have to be polished to achieve mirror or extremely smooth finishes. For production tooling, material density of a finished part or insert should be addressed prior to use. For example, in injection molding inserts, any surface imperfections will cause imperfections in the plastic part, and the inserts will have to mate with the base of the mold with temperature and surfaces to prevent problems.

In this process metallic support structure removal and post processing of the part generated is a time consuming process and requires use of EDM and/or Grinding Machines having the same level of accuracy provided by the RP machine. Also for converting .stl file (generated from Solid works / Catia) need further conversion in .cli & .sli file (these format required for RP machine). The software like "Magics" which is convert .stl file in to .sli file is also costly and add direct cost in part manufacturing.

Materials:
Currently available alloys used in the process include 17-4 and 15-5 stainless steel, maraging steel,cobalt chromium, inconel 625 and 718, and titanium Ti6Alv4. Theoretically, almost any alloy metal can be used in this process once fully developed and validated.