3D Printing/ Additive Manufacturing
What are the basics of 3D Printing?
3D printing is nothing but the process of manufacturing three-dimensional solid objects using a digital design. Its termed as an Additive manufacturing process because it involves the process of adding layers of material upon each other until the final object is created. It converts the 3D design data into real-life objects through the deposition of several layers of material. AM is the scientific name of 3D printing practices used in the market to differentiate the material removal methods commonly used in the manufacturing industry. Machining is a great example of a material removal process, as compared to Additive manufacturing which is a material addition process.
How does 3D printing work?
We design an object in CAD software
- The design is made in layers, also known as ‘Slicing’. Slicing is done using a dedicated software or through options provided in the CAD software itself.
- We send this design file to 3D printer in .STL format and the object is printed.
We can use 3D printing process to manufacture interlocking features on a part which doesn’t need any assembly of several parts. If an assembly has 10 parts involved through traditional manufacturing process, then 3D printing can help manufacture the same assembly in one single object in one go.
Following are the 9 common types of Additive Manufacturing technologies.
- FDM – Fused Deposition Modeling
FDM is one of the most common forms of additive manufacturing techniques. This was invented in 1980’s. We use the same.STL file using a 3D software in this process. The 3D printer squeeze melted thermoplastics through a high-precision small nozzle to create the object.
- SLA – Stereolithography
SLA uses a focused UV light for the transformation of liquid photopolymer plastic into a solid form.
- DLP – Digital Light Processing
DLP uses a liquid Ultra Violet photopolymer resin which solidifies one layer at a time
- SLS – Selective Laser Sintering
SLS uses a powder container of small particles. A high-powered laser follows the path of a determined trace of the object for each layer as per the CAD data.
- SLM – Selective Laser Melting or DMLS – Direct Metal Laser Sintering
SLM or DMLS is also another commonly used metal 3D printing technology that emerged in the 1980s. The product is formed by a laser that selectively melts successive layers of powder as per the tracing of the part.
- EBM – Electron Beam Melting
EBM is another type of metal of 3D printing where the raw material being a metal powder or wire is placed under a vacuum. The raw material is then fused through heating by an electron beam.
- DED – Direct Energy Deposition
DED process melts the material using a laser or another energy source while the material is being deposited. These machines work on a similar principle as material-extrusion machines with the exception that instead of melting a material through a nozzle in material extrusion, DED melts the wire or powder feed while its being deposited on the part.
- LOM – Laminated Object Manufacturing
LOM is a unique process, unlike other 3D printing techniques where instead of layers of powders with melting pools, lamination cuts out the individual layers of material and later on combines them on top of one another using a form of glue. Plastic sheets or metal foils or even common paper can be used to manufacture laminated objects.
- BJ – Binder-Jetting
BJ technology for metal 3D printing uses a nozzle to print material. But instead of printing directly with build material, the printed material is more like glue or wax which holds the powder together in the form of the object of the desired shape. This object is then sintered to melt down the glue or wax to form a finished metal object.
Detailed description of Binder-Jetting
Below is a great description of Binder Jetting technology where the binder printer uses an ink-jet spray to apply rapidly solidified binder on a powder bed. This creates a new solid object through this sprayed glue mixed with base powder material. Once metal powder layer is rolled on the build tank, another layer of liquid binder is sprayed on this metal powder along the desired object area. These two steps are repeated alternatively to get the desired shape of object. Once all the layers are complete, the additional metal powder is vacuumed and removed to re-use it for the next part. And the binded part also called as the green part is now debinded and sintered to get the final metal object.
Binder-Jetting Process
What are the design guidelines for metal 3D printing?
Following are the most important design guidelines to be considered for 3D printing of metal parts. INDO-MIM specializes in manufacturing of 3D printing through Binder Jetting and SLM or DMLS technologies.
- The part needs to weigh between 10~500 gms
- Minimum wall thickness of 0.80mm can be accommodated
- As sintered surface finish of 250 Microinches can be achieved
- Its important to have an easy removal or outlet for loose and unwanted metal powder.
- A generous corner radius, smaller L/D ratio on all features is recommended.
- A part feature resolution of less than 0.20mm is difficult to achieve.
Why is INDO-MIM your best service provider for metal 3D printing?
Nevertheless, INDO-MIM engineers specialize in producing DFM’s for 3D printed parts and will make sure your finished part is as close to the desired features. All we need is a 3D model and 2D prints from you for our review.
The San Antonio plant in Texas, USA has a dedicated 3D printing room with a dedicated 3D printing team working round the clock to fulfill the demands of 3D printing industry. INDO-MIM has aggressively invested in a Desktop Metals P1 model with a build box of 300mm x 200mm x 100mm. We have dedicated this printer to manufacture materials of SS 17-4PH & M2 Steel. More materials will be added soon.
Another recent addition of SLM-500 DMLS printer has enabled INDO-MIM to add greater value to customers by offering them parts manufactured in a buildbox of 500mm x 280mm x 365mm. The material offered for this machine is Inconel 625 and we have other materials getting added soon.
Click below link to know more about Binder- Jetting
