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Why choose 3D Metal Printing/Direct Metal Laser Sintering (DMLS)?
Metal 3D printing has grown in prominence in recent years due to its ability to create complex geometries and structures that are not feasible with traditional metal manufacturing processes. This technology allows for the production of small and large intricate parts, as part of a process that offers design freedom impossible through conventional manufacturing methods.
The metal 3D printing process produces parts with exceptional mechanical properties. These parts are as strong and as dense as those produced using wrought materials, making them ideal for tough functional prototypes. For example, when Ti64 parts are built on an M290 machine, mechanical and density testing results demonstrate that they can match or even surpass the standards set by ASTM F2924 and ASTM F3001. Additionally, both raw and heat-treated Ti64 parts from our M290 machine exhibit mechanical properties that can achieve minimum values given by sheet and wrought bar standards AMS 4911 and AMS 4928.
Another significant advantage of metal 3D printing with DMLS is the potential to reduce time to market. Since components require no tooling, design changes can be implemented rapidly. This allows parts to be manufactured overnight and put into use within days. As a result, metal 3D printing is revolutionizing the way industries approach the design and production of metal parts, offering greater flexibility and efficiency than ever before.
Unsure if DMLS is the right technology for your project?
View our process comparison tableTechnical specifications
| Standard lead time: | 5-7 days. If your project is urgent, please let a member of sales team know so that we can investigate if anything can be done to improve the lead time |
|---|---|
| Minimum feature size: | Normal resolution: 0.2mm High resolution: 0.1mm |
| Layer thickness: | Normal resolution: 0.03-0.06mm High resolution: 0.015-0.025mm |
| Tolerances: | Typically, expected tolerances on well-designed parts are: Normal resolution: +/- 0.10/100mm High Resolution: +/-0.10/100mm |
| Max part size: | Normal resolution : 250 x 250 x 305mm High resolution : 90 x 90 x 90mm |
| Machines: | EOS M290 | Concept Laser Hi Res MLabs |
Please note figures provided above are expected tolerances, we cannot guarantee part tolerance.
Materials
Stainless Steel 316L
- Tough material with good thermal and mechanical properties
- Acid and corrosion resistant
- High ductility
- Maximum part dimensions: 90 x 90 x 90mm
Aluminium AlSi10Mg
- Aluminium alloy that combines good strength, hardness and dynamic properties
- High corrosion resistance
- Ideal for applications that require low weight
- Good thermal and electrical conductivity
- Properties can be modified with heat treatments
- Maximum part dimensions: 250 x 250 x 300mm
Titanium Ti64
- High strength-to-weight ratio alloy
- Wear and corrosion resistant
- Great fracture toughness and fatigue resistance
- Excellent biocompatibility
- Available as Grade 5 (our standard material) and Grade 23 (ELI) (on request)
- Maximum part dimensions: 250 x 250 x 300mm
Hardening Stainless Steel 17-4 PH
- Precipitation hardened stainless steel known for its high strength and good mechanical properties
- Excellent chemical resistance
- Can be heat treated to maximise strength and hardness properties
- Maximum part dimensions: 90 x 90 x 90mm
Maraging Steel MS1
- Excellent mechanical properties
- Ultra high-strength
- Easily heat-treatable for enhanced strength and hardness
- Maximum part dimensions: 250 x 250 x 300mm
Finishing Options
LPE has a team of experienced in-house traditional model makers and CNC machinists allowing us to offer our customers a range of post processing options for our 3D printed metal parts.
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Standard
Components produced using the DMLS process are sanded to remove support structures and build lines but additional finishing may need to be requested if a smooth finish is required.
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Polished
Metal parts can be polished to provide surface finish under 1 Ra um.
LPE have developed proprietary techniques to facilitate advanced surface finishing of metal parts which can be used when superior surface finish of metal parts is required.
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Post machining
LPE has 5axis and 3axis CNC machines in-house along with EDM machines which means we can offer post processing of our DMLS components to meet tight engineering tolerances.
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Heat treatments
LPE has a Nabotherm LH216/12 gas controlled furnace in-house which can be used to offer thermal post treatment for both reactive and non-reactive metals (ASTM F2924). These treatments can facilitate improved mechanical properties and stress relieving benefits.
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Tapping and reaming of metal parts
Metal parts can be hand tapped or reamed to facilitate tight fittings for assembly tolerances.
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.
As part of our production manufacturing process we can offer:
- 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)
Applications
Metal Sintering is suitable for low volume production and one- off prototypes.
Prototypes in production- grade materials
Aerospace and Automotive Components
Tooling Inserts for Plastic Moulding & Die Casting
High Temperature Applications
Medical Devices
Dental Devices
Acid & Corrosion Resistant Prototypes
Plant Engineering components
Heat exchangers and heatsinks
Functional end-use production parts
Why LPE?
Our in-house additive manufacturing facilities consist of multiple state-of-the-art metal 3D printing machines with optimised machine parameters and a wide range of materials offering superior mechanical properties. We offer metal sintering parts in high resolution.
LPE are an ISO 9001 & 13485 approved supplier, with over 30 years of industry experience. We have developed qualification routes for AM production components. If requested we can provide first article inspection reports, certificates of compliance, PCD documents, machine quality reports, MILL certificates and will work with you to ensure any quality requirements in relation to your production requirements are met.
We pride ourselves on being at the forefront of this emerging 3D printing technology and have been actively involved in R&D in this field for several years. We utilise enhanced simulation software ensuring that complex parts build correctly first time.
Our in-house post processing abilities are second to none and include post machining and inspection capabilities (5axis and 3axis CNC machines along with CMM), heat treatments, mechanical tensile and density testing capabilities, metal polishing expertise and advanced finishing techniques.
Customer service lies at the heart of everything we do at LPE, from tailored quotes to a personalised service. If you feel you could benefit from chatting directly to an expert about your project, contact us now.
Learn more about why you should choose LPE as your preferred DMLS 3D Printing partner.
Learn moreHow does Metal 3D Printing work?
The Direct Metal Laser Sintering (DMLS) process is an emerging metal 3D printing technology in which 3D CAD data is converted into physical solid models, layer by layer, by selectively fusing areas of metal powder with a powerful laser.
Initially the DMLS machine laser will be aimed onto a bed of metallic powder and it will draw the support structures required onto the build plate, then it draws the part itself. Each time a layer is sintered, the build plate will drop and a recoater blade will move across the platform to deposit the next layer of powder to be sintered. This process repeats layer by layer until the entire part has been built. When the build is completed the build platform is removed and loose powder is brushed away. While the parts are still attached to the build plate they may receive heat treatment or shot peening. Parts are then typically removed from the build platform using either a saw or EDM. Parts will then ready to be post machined, barrel rumbled or hand finished.
Metal 3D Printing FAQs
What are the advantages of metal 3D printing over traditional manufacturing methods?
What industries commonly use metal 3D printing?
What types of metals can be used in 3D printing?
How strong are metal 3D printed parts compared to traditionally manufactured parts?
How accurate is metal 3D printing?
What is the typical lead time for a metal 3D printed part?
Can metal 3D printed parts be post-processed?
How much does metal 3D printing cost?
The cost of metal 3D printing depends on factors such as the size and complexity of the part, material used, and the required post-processing steps. In general, metal 3D printing can be more cost-effective than traditional manufacturing methods for low-volume production, complex geometries, and customised parts. To get an accurate estimate for your specific project, contact LPE today, or request a quote below.
