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DMLM - Direct Metal Laser Melting


GPI Prototype is a service provider of Direct Metal Laser Melting (DMLM), the latest technology for 3d printing and additive manufacturing of metal parts. As one of the first DMLM service providers in the country, GPI produces metal parts for applications ranging from prototypes to production. DMLM technology is ideal for a variety of applications including the creation of conformal cooling channels for injection molding tooling. DMLM is also known by the acronym DMLS, although the process results in full melting of the metal powder, so we have begun to use the more appropriate DMLM acronym.


Utilizing the DMLM process, metal parts of the most complex geometries are built layer-by-layer (down to 20 microns) directly from 3D CAD data. Parts built using DMLM have excellent mechanical properties equivalent to wrought materials, high detail resolution, and exceptional surface quality. The metal powder is melted entirely to create a fully dense, fine, homogenous structure. Unique geometric freedom of design enables DMLM to form cavities and undercuts, which with conventional machining methods, can only be produced with great difficulty, if at all.

Additionally, when a part needs to be tested and re-designed over and over, the lead time for receiving a traditionally tooled part can create a large bottleneck in the final production process. DMLM produces parts that are extremely high quality and can be built in a matter of hours or days rather than weeks. The ability to generate functional metal prototypes in short order radically impacts design processes, accelerating design cycles and time to market.

Depending on size and geometries, in some cases the turnaround time for a part can be as little as a few hours. Furthermore, these parts can undergo functional testing in the environment for which they were designed. This technology delivers unlimited potential for engineers to create previously impossible solutions, embracing a new era of design-driven manufacturing.


DMLM MACHINES:

GPI Prototype currently has ten DMLM machines at our Lake Bluff, IL facility. There are six machines from EOS including two EOSINT M 270 machines, two EOSINT M 280 machines, and two EOSINT M 290 machines. We also have four direct metal printers from 3D Systems including two ProX 200 machines, one ProX 300, and one ProX 320.



DMLM IMAGES:



DMLM MATERIALS: Click on the material type to view a data sheet.

Material Characteristics Advantages / Applications

Stainless Steel (PH1)


• 15-5 Mechanical Properties
• 20 or 40 Micron Layers
• 30-35 HRC Built
• Post Hardened to 40 HRC

• Prototype / Production Parts
• High Toughness, Ductility, Strength

Stainless Steel (GP1)


• 17-4 Mechanical Properties
• 20 or 40 Micron Layers
• 250 HV Hardness

• Prototype / Production Parts
• Good Mechanical Properties

Cobalt Chrome (MP1)


• CoCrMo Superalloy
• 20, 40 or 50 Micron Layers
• 35-45 HRC Built

• Turbines & Engine Parts
• High Temperature Resistance

Maraging Steel (MS1) - Tooling Steel


• Maraging (Tooling) Steel
• 20 or 40 Micron Layers
• 33-37 HRC Built
• Post Hardened to 50-54 HRC

• Injection Molding Tooling
• Conformal Cooling Channels
• Easily Machinable & Excellent Polishability


Aluminium AlSi10Mg

• Good Strength & Hardness
• Low Weight
• Good Thermal Properties

• Low Weight Applications
• Automotive & Racing Applications
• Thermal Parts

NickelAlloy IN718


• Nickel Based Heat Resistant Alloy
• 40 Micron Layers
• 30 HRC Built
• Post Hardened 47 HRC

• Turbine Engines
• Rocket & Aerospace Applications
• Chemical Industry Parts
• Heat & Corrosion Resistant

Stainless Steel (316L)
• High ductility and toughness
• Low Carbon
• 20 or 30 Micron Layers

• Corrosion & Pitting Resitant
• Good Weldability
Titanium Alloy Ti-64 - Data Sheet Coming Soon • Corrosion Resistant
• High Strength & Light Weight
• 30 or 60 Micron Layers

• Aerospace & Motor Racing Parts
• High Performance Engineering Applications



DMLM FINISHING:

From left to right: Raw Finish, Shot Peen, Shot Blast, Mirror Polish, Medium Polish, Brush Finish

finishing

 

FILES:

Filename Size
An Adobe Acrobat file Case Study - SEDS at UCSD DMLS Rocket Engine 2.02 MB
An Adobe Acrobat file DMLS Design Rules 1.05 MB
An Adobe Acrobat file EOSINT M 270 Brochure 88.99 KB
An Adobe Acrobat file EOSINT M 280 Brochure 1.7 MB
An Adobe Acrobat file EOSINT M 290 Brochure 1.13 MB
An Adobe Acrobat file Finishing Options for Direct Metal Laser Sintering (DMLS) 305.35 KB
An Adobe Acrobat file Whitepaper - Conformal Cooling Using DMLS 929.85 KB
An Adobe Acrobat file Whitepaper - Mechanical Testing of DMLS Parts 1.6 MB
An Adobe Acrobat file Whitepaper - Optimised Mould Temperature Control Procedure Using DMLS 519.35 KB


If you are looking for fast metal parts with excellent mechanical properties, high resolution and exceptional surface quality, please give us the opportunity to quote your next project.

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