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3 articles: edm cnc and dmls
EDM

CNC

DMLS

2 (changed)

DMLS is an additive fabrication process which uses a focused high-power laser beam to fuse a metal powder which is specifically created to create component using the DMLS process. Similar to other additive technologies (e.g. SLS, Stereolithography), the machine must be provided with the 3D Cad Data of the desired shape, after which the machine divides the 3D Cad Data into horizontal layers and the fabrication process is performed onto a tray which is automatically lowered after the creation of each level ultimately creating the part layer-by-layer until the desired component has been left to be put through certain finishing stages before it is ready to to be used, evaluated, tested etc.

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DMLS was developed jointly by Rapid Product Innovations (RPI) and EOS GmbH. (the leading manufacturer of laser-sintering systems) It is a a fairly young technology. The development of Direct Metal Laser Sintering (DMLS) was started in 1994 and the goal was to develop the first commercial rapid prototyping method for metal parts.
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1 about dmls and decision making process

how the tool will be constructed
-evaluation of criteria
-such as leadtime, the complexity of the tool. required tolerances, desired material for the actual product being fabricated

DMLS is chosen more and more often
-reasons:
-technology allows for complex designs not possible to fabricate using more traditional processes
-the awareness of such technologies not only enamble designers but encourage them to create more complex parts and products which ultimately leaves the customer with a better product.

3-D CAD model of the part, or parts, that are being fabricated

dmls has advantages:
-allows for the simulatieous fabrication of multiple parts
-machine unattended 24 hours a day

-extremely accurate, intricate and complex shapes
-usually tool inserts but also often for metal components
-beneficial for creating tooling for manufacturing processes such as pressure die casting, liquid injection molding and several other technologies.
-the ability to create conformal cooling lines in the tool.... a real advantage
-heavliy reduces the occurance of oxidation during the manufacturing process

dmls has disadvantages:
size of the tray limits the size of the mold or part being created so larger molds cannot be created using the dmls process
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2 extra (and unchanged)

The components can be prototypes, series production parts or even spare parts.

In addition, the metal components are durable enough to serve as functional prototypes. High accuracy ([+ or -] 0.05 mm) and detail resolution (20 [micro]m layer thickness) possible with the fine-grained powders offer significantly ...

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It is a net-shape process, producing products with high accuracy and detail resolution, good surface quality and excellent mechanical properties.

Direct metal laser sintering is quickly gaining recognition as perhaps one of the most enhancing technologies available in the additive fabrication arena today.

But as DMLS is becoming a more mature manufacturing technology and becoming faster, more and more components will be manufactured using this technique.
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3 process

The DMLS process can be divided into two different categories as there are two different methods of applying powder when building layers. The first is referred to as the powder deposition method. During the powder deposition method, the metal powder is contained in a hopper which is used to melt and deposit the powder onto the build platform. This method allows the use of multiple materials as they can be contained in multiple hoppers that each deposit their own materials. The second method is called the powder bed method. In this method, the powder supply is raised by the powder dispenser piston and because only one material is being used, the powder bed method builds components and a substantially quicker rate than the powder deposition method.

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The thickness of the layers depends on the material used and ranges from 20 to 60 microns.
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3 process extra

The process begins by sintering a first layer of 20-micron powder onto a steel platform.
The supports and components are built with a layer thickness ranging from 20 to 60 microns, depending on the material used.

Each layer is scanned with the laser fusing the powder to the previous layer below it, and forming the new build layer. The base is then lowered one layer, a fresh layer of powder is deposited, and the next layer is scanned. A powerful 200W Yb-fibre laser is precisely controlled in the X and Y co-ordinates allowing for exceptional tolerances to be held (<+/-0.1mm).
The platform then lowers by 20 microns, a fresh layer of powder is swept over the previously sintered layer, and the next layer is sintered on top of the previously built one.
A powerful 200W Yb-fibre laser is precisely controlled in the X and Y coordinates—allowing for exceptional tolerances to be held (+/-0.001"/inch). The latest technology takes advantage of a dual spot laser allowing feature sizes as small as 0.203mm (0.008") to be built. The latest technology takes advantage of a 'dual-spot' laser allowing feature sizes as small as 0.4mm to be built. With a machine build envelope of 250x250x215mm (including platform), many medium to small parts and inserts are able to be constructed in hours and days versus days and weeks using traditional processes.

14 post extra

It builds parts layer by layer and it operates fully automatically and completely unattended.

Once started, the machine builds unattended, 24 hours a day.
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14 post

-Once completed, the build platform with the tooling inserts or components are removed from the steel platform and post operations, such as polishing and other traditional tooling steps, are performed on the components before they are mated up with other tooling items.
-Parts and inserts that come out of the machine typically will go through a series of ‘post’ steps including support removal, shot peening, etc.
-Parts and inserts that come out of the machine typically will go through a series of 'post processing' steps including support removal, shot peening and polishing.
-Parts and inserts that come out of the machine typically will go through a series of post steps including support removal, shot peening, etc.
-less post processing than traditional CNC machining
-The parts coming out of the machine are 100 percent sintered and require no post-sintering or other infiltration process.
-The parts coming out of the machine are 99.99% dense and require no post-sintering or other infiltration process.
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4 advantages extra

This ability to create non-machinable or indeed, previously un-manufacturable forms means that the design of components can be much more flexible than is traditionally the case

Direct metal laser sintering is now an established method for the production of functional prototypes and mold inserts using computer-controlled laser/scanning with a powder feed system.

Typical geometries produced by DMLS are difficult-to-manufacture components and components typically produced by P/M or even by die-casting.

Although using thinner layers also increases the building time the advantage is gained in drastically reduced finishing times due to increased surface quality and detail resolution.

The term Rapid Manufacturing is today very often used as a substitute for Rapid Prototyping, because the manufacturing processes and materials have developed so much that the parts produced with the machines can even be used as functional production parts.