Direct Metal Laser Sintering (DMLS)

GPI Prototype is a service provider of Direct Metal Laser Sintering (DMLS), the latest technology in rapid prototype and direct digital manufacturing services. As one of the first DMLS service providers in the country, GPI produces metal parts for applications ranging from prototypes to production tools. DMLS technology is ideal for a variety of applications including the creation of conformal cooling channels within tools and tooling inserts, as well as customized medical implants.

Utilizing the DMLS process, metal parts of the most complex geometries are built layer-by-layer (down to 20 microns) directly from 3D CAD data, automatically, without tooling. The parts have excellent mechanical properties, high detail resolution and exceptional surface quality. The metal powder is melted entirely to create a fully dense, fine, homogenous structure. Unique geometric freedom of design enables DMLS to form cavities and undercuts which, with conventional methods, can only be produced with great difficulty, if at all.

Additionally, when a part needs to be tested and re-designed over and over, the lead time for receiving a traditionally tooled part can create a large bottleneck in the final production process. DMLS produces parts that are extremely high quality, and can be built in a matter of hours or days rather than weeks. This ability to generate functional metal prototypes in short order radically impacts design processes, accelerating design cycles with time to market by creating the opportunity for multiple redesigns and builds.

Depending on size and geometries, in some cases the turnaround time for a part can be as little as a few hours. Furthermore, these parts can undergo functional testing in the environment for which they were designed. This technology delivers unlimited potential for engineers to create previously impossible solutions, embracing a new era of design-driven manufacturing.

MACHINES:

EOS M280 (uses Argon when using titanium, aluminum and Inconel (Grade 650 and 718) and nitrogen)

EOS M270 (only uses nitrogen)

Machine size (X x Y x Z): multiply Z by 25 to find max, cannot exceed 182mm (talk with Scott if close to see if build can be done on angle)

M280 = 9 x 9 x 12’’ or 228 x 228 x 304 mm 

M270 = 9 x 9 x 7.5’’ or 228 x 228 x 190 mm

Feature size = .015’’ or .38 mm

Minimum wall thickness is .3mm - .4mm or .012” - .014”

Resolution = 20/40 microns STANDARD OR HIGH???

Typical tolerances are .005 on 1^st inch, .002 thereafter or .127 - .050 mm

Beam thickness: .008’’ or .2032 mm

MATERIALS (MOST COMMON):

Stainless Steel (Ph1)

Grade is 15-5 (chrome content) or industry standard

Hardness (HRC) 30 – 35, if post hardened up to 40 HRC

Thermal conductivity 13.8 +/- .8 W/mC

Heat capacity 460 degrees C, 470 degrees C if hardened

Layer thickness 20 microns or .02 millimeters         

Stainless Steel (GP1)

Grade is 17-4 (chrome content) or industry standard

Hardness (HRC) 20 – 25, if post hardened up to 45 HRC

Thermal conductivity:

20 degrees C = 13 W/mC

100 degrees C = 14 W/mC

200 degrees C = 15 W/mC

300 degrees C = 16 W/mC

Heat capacity 550 degrees C. Post-process stress-relieving @ 650 degrees C for 1 hour.

Layer thickness 20 microns or .02 millimeters

Cobalt Chrome (MP1)

Grade of chrome content???

Hardness (HRC) 35-45, then stress relieved

Thermal conductivity:

20 degrees C = 13 W/mC

300 degrees C = 18 W/mC

500 degrees C = 22 W/mC

1000 degrees C = 33 W/mC

Heat capacity 1150 degrees C. Post-process stress-relieving @ 1050 degrees C for 2 hours.

Layer thickness 20 microns or .02 millimeters

Maraging Steel (MS1)

Grade of chrome content???

Hardness (HRC) 33-37, 50-54 after age hardening for 6 hours

Thermal conductivity 15 +/- .8 W/mC

Heat capacity 450 degrees C

Layer thickness 40 microns or .04 millimeters (Under development) 20 microns or .02 millimeters

AVAILABLE METAL MATERIALS: Click on the material type to view a data sheet.

Finishes:

1) Shot peened (Media = ceramic and metal beads)

2) Shot/Sand blasted (add .001 material), (Media = aluminum beads)

3) Brush finish (polish 1^st)

4) Light sanded (no extra material needed)

5) Medium polished (add .003 - .008 material)

6) Mirror finished

DMLS can build both functional and visual parts but 90% are functional.

* Conformal Cooling PDF
* EOS M270 PDF
* Mechanical Test Data PDF
* Finishing Options for Direct Metal Laser Sintering (DMLS)