Direct Metal Laser Sintering (DMLS) is a robust and widely used metal additive manufacturing process with many similarities with the SLM method. In the DMLS process, the machine sinters the powdered material following the instructions of the CAD file. However, the main difference is that DMLS does not melt the metal powder fully. Due to this difference, the filament does not arrive at a high temperature and the cooling time is lower in this process.
The most significant benefit of DMLS is that it's more convenient for producing 3d printed components. As a result, DMLS-printed items are commonly used in automotive, aerospace, and more.
Powder bed fusion
It's among the widely-employed metal 3d printing process that is scalable, robust and offers consistent production. In powder bed fusion technologies, the 3d printer distributes the layers of powder metal evenly on the printing bed. The electron beam or the layer then selectively fuses the metal particles.
There are primarily two categories of powder bed fusion technology. First is selective laser melting (SLM) and direct metal laser sintering (DMLS). In addition, the second category is electron beam melting or EBM.
Direct energy deposition
In the DED process, a 3D printer works by melting the metal filament using a powerful laser, and it's deposited on the build platform via a nozzle. As a result, direct energy deposition printers have a higher material deposition throughput, and they can work in both wire and powder form. In addition, the DED method can create heavier and intricate parts with top-notch accuracy.
DED metal printing technology is ideal for repairing heavy industrial equipment and machinery. For example, companies can quickly repair parts like turbine blades, a motor's internal equipment, or injection moulding's inserts.
Metal binder jetting
This printing technology is a cost-optimized method that is similar to conventional ink printing on paper. The metal 3d printer uses a printing head that moves over the build platform. The print head deposited the binding agent's droplets onto the metal powder layers. In this process, the 3d printer fuses the metal particles to create a physical component.
For making the printing process faster, many printers support the use of multiple printing heads. However, the components built have limited mechanical properties due to their printing method, and the surface is also porous. It happens because the binder gets burned out during the manufacturing process. Due to this, metal binder jetting parts need to undergo significant post-processing. Some widely-used post-processing steps include bronze infiltration, curing, and porosity reduction.
Ultrasonic sheet lamination
It is a hybrid metal 3d printing technology that operates at a lower temperature. This technology works by welding together thin metallic foils using ultrasonic vibrations under pressure. After the printing process is completed, engineers use the CNC milling method to chip off excessive material.
As the ultrasonic sheet lamination operates at a lower temperature, the machines don't melt the metal. This technology can also fuse different metal types to achieve the desired properties. The fundamental advantage of using ultrasonic sheet lamination is its low cost and faster turnaround time. In addition, manufacturers can also build parts with embedded electronic sensors. Therefore, it's ideal for printing metal-based electronic components.
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