Design for Metal 3D Printing

Dear Desktop Engineering Reader:

The press chronicles 3D printing with thermoplastics like a rock star. It should. It's great stuff. But additive manufacturing offers more beyond thermoplastics. Terrific things are possible with metal, particularly with DMLS (Direct Metal Laser Sintering) technology. Today's Check it Out link directs you to a white paper explaining how you can better design for DMLS 3D printing. If you just want to learn more about DMLS, you are not going to find a better introduction.

“Getting the Most Out of Metal 3D Printing: Understanding Design & Process Controls for DMLS” from Stratasys Direct Manufacturing, the 3D printing and advanced manufacturing services arm of Stratasys, covers metal 3D printing design freedoms and constraints, materials, quality and process controls, surface finishes and heat treatments. While it sometimes explains how Stratasys Direct Manufacturing handles a process step, this paper is decidedly written from the design engineer's point of view, making it fascinating regardless of your familiarity with DMLS or the company's services.

The paper makes the case for DMLS additive manufacturing: Designers have all the design freedom of thermoplastic 3D printing, but can print with metal. You can manufacture complex designs that casting and machining can't do or, if they can, are cost- and time-prohibitive. Final products can have the mechanical properties of aerospace standard materials.

Next is an overview of DMLS mechanics, then it's everything design. First stop looks at materials, which include everything from nickel and copper alloys to pure titanium. The focus here is on how designs affect a part's mechanical performance. This segues to granular discussions on angles, self-support structures, built-in internal channels and no-access features. Multiple illustrations enhance each topic, and abundant design tips will have you taking notes.

Metal 3D printing design constraints and freedoms, materials, finishes and heat treatments are among the topics covered in the complimentary white paper “Getting the Most Out of Metal 3D Printing.” Image courtesy of Stratasys Direct Manufacturing.

Post-processing is next. First, it covers stress relief before removing parts from the build platform, then secondary heat treatments like HIP (hot isostatic pressing), SHT (solution heat treatment) and PHT (precipitation hardening treatments), which can produce parts with properties near to wrought metals.

The paper brings home the potential of DMLS 3D manufacturing with a one-page case study about a fuel injector built for the Marshall Flight Center. The time comparison with conventional manufacturing will impress any remaining skeptics.

The short of it is that “Getting the Most Out of Metal 3D Printing” is an excellent way for you to learn about DMLS 3D printing and to improve your design skills. Hit today's Check it Out link and download your complimentary copy.

Thanks, Pal. – Lockwood

Anthony J. Lockwood

Editor at Large, Desktop Engineering

Download “Getting the Most Out of Metal 3D Printing: Understanding Design & Process Controls for DMLS” here.