Direct Metal Part Production
Shown is a breakdown of each of the major methods of direct metal part production, as well as
details on each of the processes. Major suppliers of the technologies also are provided.
SLM—Selective laser melting
(SLM) is a process that produces fully dense metal parts by melting fi ne metal powders with a high power fi ber laser in a controlled atmosphere. SLM machines currently on the market can process stainless steel 316L and 17-4PH; H13 tool steel; aluminum Al-Si-12Mg and Al-Si-10Mg; titanium CP, Ti-6Al-4V and Ti-6Al-7Nb; cobalt-chrome (ASTM75), and Inconell 718 and 625. DMLS—Direct metal laser sinter-
ing (DMLS) produces metal parts out of fi ne powders using a fi ber laser in an inert atmosphere. The DMLS systems currently available can produce parts out of aluminum Al- Si10Mg, UNS R31538 of high carbon CoCrMo alloy, bronze-based alloys, martensite-hardenable steel, nickel alloy IN718 and DIN NiCr19Fe19N- bMo3, stainless steel U.S. classifi ca- tion 17-4 and 15-5 PH, and titanium Ti6Al4V alloy. 3D Printing—3D printing works
by selectively binding powder grains with an inkjet print head. The ink causes the powder to be glued together, and parts are built from the bottom up, cross section by cross section. 3D printing can be used to form metal parts, sand or ceramic molds, ceramic parts and patterns for tooling. Compared to other processes, 3D printing systems are usually the cheapest and fastest options but produce weaker parts. FDM—Fused deposition model-
ing (FDM) creates a 3D object by ex- truding a thin fi lament of material out of a nozzle, like building an object with a hot glue gun. Materials cover a wide range of polymers that can be used for making pattern tooling, and in some cases, they can be used for making investment casting patterns. FDM parts are typically strong, but they have a rougher surface fi nish due to their method of fabrication. Laser Consolidation—The laser consolidation process creates metal parts by melting metal powders to create net shape parts in a range of high strength alloys.
MC MODERN CASTING / July 2010 31
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