Direct metal laser sintering of complex metal structures

Abstract

Direct Metal Laser Sintering (DMLS) is a layered process that enables the fabrication of complex net-shape mold inserts and metal components directly from 3D CAD data. The main application areas are plastic injection molding, pressure die-casting and direct component fabrication. The metal powders for DMLS process have been developed and optimized especially for laser processing and continuous development work has brought new metal powders to the market. An important development task for EOS Finland has been to improve material and surface properties of existing materials which are based on bronze and steel powders. New finer powders have enabled the laser sintering of much finer details than previously. Significantly better surface quality and better dimensional accuracy have been obtained using the latest materials. Therefore additional post processing of sintered parts has been reduced to minimum. This paper will present the state of the art in Direct Metal Laser Sintering process, materials and applications. The aluminium pressure die-casting case study indicates the possibilities and potential of DMLS in die-casting applications.Direct Metal Laser Sintering (DMLS) is a layered process that enables the fabrication of complex net-shape mold inserts and metal components directly from 3D CAD data. The main application areas are plastic injection molding, pressure die-casting and direct component fabrication. The metal powders for DMLS process have been developed and optimized especially for laser processing and continuous development work has brought new metal powders to the market. An important development task for EOS Finland has been to improve material and surface properties of existing materials which are based on bronze and steel powders. New finer powders have enabled the laser sintering of much finer details than previously. Significantly better surface quality and better dimensional accuracy have been obtained using the latest materials. Therefore additional post processing of sintered parts has been reduced to minimum. This paper will present the state of the art in Direct Metal Laser Sintering process, materials and applic...