Direct Metal Laser Sintering (DMLS) Services

   

Metal 3D Printing

Direct metal laser sintering (DMLS) is an additive manufacturing process that can be used to create fully functional, complex metal components. It is most widely used across the Medical, Automotive and Aerospace industries.

DMLS is an emerging 3D printing technology, with the production applications for this process only developed in the last decade. This process is based on the layer-by-layer addition of powders, selectively fusing areas of each layer into parts using a powerful laser.

 

Why Choose DMLS?

DMLS is often used when the geometry or structure of a part is not possible to create in any other metal manufacturing process. The ability to manufacture small parts with exceptionally fine detail provides design freedom which is not possible with traditional manufacturing methods.

Parts created using DMLS materials tend to be stronger and denser than wrought materials and this makes them tough functional prototypes. For parts build in Ti64 on our M290 machine, mechanical and density testing results demonstrate that we can match or achieve higher results than standards ASTM F2924 and ASTM F3001. Further, for both non-HIP and HIP treated Ti64 parts from our M290 machine, mechanical results demonstrate we can achieve as good as minimum values given from sheet and wrought bar AMS 4911 and AMS 4928.

DMLS can significantly reduce the time to market. Components require no tooling which means design changes can be implemented quickly, therefore parts can be built overnight and be in use within days.

At LPE we offer a complete metal sintering service, comprising in-house printing, stress relieving, EDM, bead blasting, 5-axis post machining to tight tolerances and mechanical and physical testing. We have developed qualification routes for AM production components and have been actively involved in R&D in this field for several years. We currently offer Metal Sintering in Stainless Steel (316L), Hardening Stainless Steel (17-4Ph), Aluminium (ALSi10Mg) and Titanium (ELI grade 23 and grade 5).

 

Key Features of DMLS 

 

• High resolution parts• Heat treatments available in-house of both reactive and non-reactive metals (ASTM F2924)
• Capable of building large parts (maximum bed size 250mm x 250mm x 325mm)• Multiple EDM machines
• Parts available in stainless steel (316L and 17-4Ph), aluminium (ALSi10Mg), and titanium (ELI Grade 23 and Grade 5)• Advanced finishing techniques
• Optimised machine parameters• Metal polishing expertise
• Enhanced simulation software ensures complex parts build correctly first time• In-house mechanical tensile and density testing capabilities
• Typical density of parts >99%• Post machining and inspection capabilities (5axis and 3axis CNC machines along with CMM)
• Parts can be provided with hand-reamed holes and tapped ready for installation• Quality control system facilitates production capabilities

 

Direct Metal Laser Sintering Production

We offer a complete contract manufacturing service and qualification route that we have developed in conjunction with the standards ASTM/ISO F3301 and FF3302. Our QMS quality management system allows us to manufacture repeatable and reliable metal parts.

  • Process control documents (PCD) 
  • Powder certification and analysis (batch control, size distribution and chemical analysis)
  • Machine certification (calibration certified, in-build laser power monitoring)
  • Quality reports from each build
  • Mechanical testing
  • Physical analysis, including porosity and density, surface and dimensional analysis
  • Heat treatments certification (reports from our fully instrumented in-house inert gas box furnace)
  • Advanced heat treatment certification, hot isotonic pressing (HIP) (full cycle reporting from certified heat treatment facility, customised cycles available)

 

A Trusted DMSL Production Partner

If you require the fast production of accurate metal prototypes or parts, then choose DMLS for an efficient process. We have both high resolution (as small as 0.015mm) and standard resolution (0.06mm) to cater for our customers’ varying demands.

LPE meets the international standards of ISO 9001 and ISO 13485, and have rigorous systems in place to guarantee quality and consistency are met. To maintain critical quality control standards, we use a range of tools to inspect and ensure customer specifications. You can view our machines below.

 
 Contact Us

If you require any further information or simply wish to contact us about our DMSL Services do not hesitate to contact us.

 

Materials

A recent addition to the LPE service range. we currently offer Metal Sintering in Stainless Steel, Hardening Stainless SteelAluminium and Titanium

At LPE we continually strive to offer our customers the widest range of materials and services, we will be expanding our Metal Sintering material range in the coming months. Once new materials are available we will update our website with further information, to find out more contact our sales team on 028 9070 6940

 

Machines

Concept Laser Hi Res MlabR Machine
High Resolution machine with build capacity of 90x90x80mm
 
Building components in Stainless Steel, Aluminium and Titanium.

EOS M290 Metal Sintering Machine
Larger capacity Metal Sintering Machine with build capacity of 250x250x330mm
 
Building components in Titanium.

 

Finishes & Treatments

Metal Sintering produces components in recognised engineering metals suitable for a wide range of post production processing including;

 

      • Heat Treatments and Stress Relieving
      • Machining
      • Welding
      • Tapping
      • Polishing and
      • Plating

 

Applications

Providing 99.99% dense components, Metal Sintering parts built in Aluminium, Stainless Steel and Titanium offer a direct replacement for traditional machined components in Aluminium, Stainless Steel and Titanium and replicate almost identical mechanical properties.

The metal sintering process has proven popular for;

 

      • High Temperature Applications
      • Medical Devices
      • Dental Devices
      • Aerospace Components
      • Acid & Corrosion Resistant Prototypes
      • Plant Engineering components and
      • Tooling Inserts for Plastic Moulding & Die Casting.

 

Why LPE?

Short Lead Times:

Typical lead times for Metal Sintering is 3-6 working days unless otherwise stated.

Tight Tolerances:

Metal sintering offers an expected tolerance of +/-0.1mm to +/-0.2mm +0.005mm/mm*

Expert, Impartial Advice: 

As the first rapid prototyping bureau in the UK and Ireland, LPE has over 25 years experience converting customers designs into fully functional prototype components and with a wide range of services available, we offer impartial advise tailored to your individual project requirements.

Committed to Customer Service: 

An ISO 9001 & 13485 approved supplier, LPE consistently work towards excellence of both part quality and customer service. We endeavour to provide a fast, professional response to all customer enquiries and carefully monitor quality throughout the production process.

Rapid Delivery: 

LPE work with local couriers to offer free Next Day Delivery on all orders. For time sensitive projects speak to the sales team about A.M. and Saturday delivery.

 
 

*Due to the nature of the process we are unable to guarantee tolerances, figure quoted above is a guideline only.

Testimonial

“If your future model remains as it is, I think you are already providing a first class facility. I would certainly not hesitate to recommend your company to anyone looking for a fast, good quality prototype”


Customer Testimonial - GPT