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Rapid-Cast Metals - DMLS Parts
The DMLS (Direct Metal Laser Sintering) additive manufacturing process produces metal components direct from a CAD model using a powerful 200w Yb-fibre laser on the New EOSINT M 270 (250w CO2 laser on the EOSINT M 250 Xtended) and layers of fine metal powder.
A CAD model is sliced into 0.020mm layers and effectively reconstructed layer by layer with the laser fusing or melting each layer to the one below. In this way the system can build any geometry, unlike a ‘line-of-sight’ material removal process like CNC machining, which would require the support of EDM to achieve certain shapes.
Consequently, very complicated or involved geometries can be obtained, including voids, tunnels and undercuts as the ‘unsintered’ powder is literally shaken out and reused.
The DMLS process is also used by CRDM Limited for the manufacture of rapid low-cost plastic injection and also pressure die-cast tooling and press tooling.
Materials currently available:-
Stainless Steel GP1
Stainless Steel GP1 is a pre-alloyed stainless steel in fine powder form. Its composition corresponds to US classification 17-4 PH and European 1.4542 and fulfils the requirements of AMS 5643 for Mn, Mo, Ni, Si, C, Cr and Cu. This kind of steel is characterized by having very good corrosion resistance and mechanical properties, especially excellent ductility in laser processed state, and is widely used in a variety of engineering applications.
Stainless Steel PH1
Stainless Steel PH1 is a pre-alloyed stainless steel in fine powder form. This kind of steel is characterized by having very good corrosion resistance and excellent mechanical properties, especially in the precipitation hardened state. This type of steel is widely used in variety of medical, aerospace and other engineering applications requiring high hardness, strength and corrosion resistance.
This material is ideal for many part-building applications (DirectPart) such as functional metal prototypes, small series products, individualised products or spare parts. One potential application is injection moulding tools for processing of corrosive plastics.
Standard processing parameters use full melting of the entire geometry with 20 µm layer thickness, but it is also possible to use 40µm layer thickness to increase the build speed. Using standard parameters the mechanical properties are fairly uniform in all directions.
Parts made from Stainless Steel PH1 can be machined, spark-eroded, welded, micro shot-peened, polished and coated if required.
Maraging Steel MS1
Maraging Steel MS1 is a pre-alloyed ultra high strength steel in fine powder form. Its composition corresponds to US classification 18% Ni Maraging 300, European 1.2709 and German 3NiCoMoTi 18-9-5. This kind of steel is characterized by having very good mechanical properties, and being easily heat-treatable using a simple thermal age-hardening process to obtain excellent hardness and strength.
This material is ideal for many tooling applications (DirectTool) such as tools for injection moulding, die casting of light metal alloys, punching, extrusion etc., and also for high performance industrial and engineering parts, for example in aerospace and motor racing applications.
Standard processing parameters use full melting of the entire geometry, typically with 40 µm layer thickness, but it is also possible to use Skin & Core building style to increase the build speed. Using standard parameters, the mechanical properties are fairly uniform in all directions.
Parts built from Maraging Steel MS1 are easily machinable after the building process and can be easily post-hardened to more then 50 HRC by age-hardening at 490 °C for 6 hours. In both as-built and age-hardened states the parts can be machined, spark-eroded, welded, micro shot-peened, polished and coated if required.
Cobalt Chrome MP1
The chemistry of Cobalt Chrome MP1 conforms to the composition UNS R31538 of high carbon CoCrMo alloy. It is nickel-free (< 0.1 % nickel content), sterilisable and suitable for biomedical applications. The laser-sintered parts are characterized by a fine, uniform crystal grain structure.
They fully meet the requirements of ISO 5832-4 and ASTM F75 for cast CoCrMo implant alloys, as well as the requirements of ISO 5832-12 and ASTM F1537 for wrought CoCrMo implants alloys except remaining elongation. The remaining elongation can be increased to fulfill even this standard by hot isostatic pressing (HIP).
Nickel-Bronze DM20
A low cost alternative to the 100% dense materials, the DM20 provides the perfect prototyping and low-volume solution to metal products. The DM20 material can be run on both the M 250 and M 270 effectively doubling our capacity for DM20 components and tooling inserts. A powerful 250w CO² laser fuses or melts together the individual layers which are evenly delivered by the recoating arm.
The end result is a 98% dense component with an excellent surface finish, manufactured to a repeatable accuracy of +/-0.05mm. DM20 is very close in characteristics to aluminium and is actually harder wearing than hard tooling aluminium.
The DM20 system has been readily used by Aerospace, F1 companies for wind-tunnel testing due to the materials rigidity and associated weight characteristics. The strength of the DM20 material has also leant itself to functional metal prototypes for the medical and automotive sectors, and low volume production components for the nuclear industry.
Typical applications:
Automotive, Aerospace & MOD
- Engineering applications including functional prototypes, small series products, individualised products or spare parts.
- Parts requiring particularly high toughness and ductility, e.g. turbines and other parts for engines, cutting parts, etc. parts having very small features such as thin walls, pins, etc.
Medical Implants & Dentistry
- Parts requiring high corrosion resistance, sterilisability, etc.
- Prototype or one-off biomedical implants, e.g. spinal, knee, hip bone, toe and dental parts.
- Parts requiring high mechanical properties in elevated temperatures (500-1000°C).
 Medical Implants
 Medical Tooling
 Production Components
 Ergonomic Models
 Working Prototypes
 Wind Tunnel Testing
 Exhibition Models
 Design Proving
 Accurate to +/-50 microns
 Delivery 5-10 days
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