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Direct Metal Laser-Sintering(DLMS)3D Printing

What is DMLS 3D Printing Service?

Direct Metal Laser Sintering (DMLS) is considered the crown jewel of 3D printing technology. This advanced technique involves the direct deposition of metal powder, which is melted by a high-energy laser. The sintering process solidifies the powder material, automatically stacking it in layers to produce solid parts with complex geometries. Unlike traditional powder metallurgy, DMLS produces dense metal parts with minimal porosity, achieving a density greater than 99%, comparable to forged materials.

DMLS has been utilized for over a decade and is commonly employed for the mass production of molds for injection molding, as well as the manufacturing of metal products. It is also applicable in other plastic processing techniques such as extrusion and blow molding. The primary advantage of DMLS is its ability to eliminate costly and time-consuming pre-treatment and post-treatment steps, streamlining the production process.

DLSM 3D Printing Process

1. Modeling and Slicing

In the DMLS 3D printing process, the first step is to create or obtain a three-dimensional digital model of the object using computer-aided design (CAD) software or 3D scanning equipment. This model is then segmented by specialized slicing software into a series of two-dimensional layers, each representing a cross-section of the object at a certain height.


2. Powder Laying and Laser Sintering

Before printing begins, the build platform is coated with a thin layer of metal powder, typically a nickel-based alloy or another superalloy. A high-power laser beam then scans this layer of metal powder along a predetermined path, as instructed by the slicing software. The laser's energy melts and fuses the powder particles together, forming a solid layer.


3. Layer-by-Layer Accumulation

After sintering one layer, the build platform lowers by the thickness of one layer, and a new layer of metal powder is applied. The laser then scans and sinters this new layer according to the next slice of data. This process repeats, accumulating layers to form the complete object.


DMLS involves two types of powder feeding: coaxial powder feeding and roller powder feeding. Coaxial powder feeding is suitable for manufacturing layered objects with a thickness of more than 1mm and large metal parts. Roller powder feeding, which offers high precision, is better suited for making small parts, although these parts are prone to heat deformation during the manufacturing process. This technique is less effective for producing larger items with complex geometries.

Advantages of DLSM 3D Printing

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1. The laser cladding layer and the substrate form a metallurgical bond, with a bonding strength of at least 95% of the original substrate material.

2. The thermal effect on the substrate is minimal, resulting in low deformation.

3. A wide range of materials can be used to meet the performance and surface characteristic requirements of different workpieces.

4. The cladding layer and its interface exhibit a dense microstructure with fine grains, free from defects such as holes and inclusion cracks.

5. It can repair valuable parts and molds of large equipment that are locally worn or damaged, extending their service life.

6. The cladding process has good controllability and is easy to automate.

7. It enables high-quality, quick repairs of damaged parts, reducing downtime and maintenance costs.

8. The hardness of the commonly used cladding layer ranges from HRC 30 to 60, with ultra-high hardness requirements reaching HRC 65 to 75. The cladding layer thickness ranges from 0.1 to 10.0 mm.

9. Metal parts can be directly manufactured using this technology.

DLMS 3D Printing Materials

DMLS (Direct Metal Laser Sintering) technology employs a wide range of metal powder materials.

Applications of DMLS 3D Printing

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