How do you choose the best DMLS material for your application?

1 DMLS process and parameters

DMLS works by scanning a layer of metal powder with a laser beam, melting and solidifying the powder according to a digital model. The process is repeated layer by layer until the part is completed. The quality and performance of the DMLS part depend on several process parameters, such as laser power, scan speed, layer thickness, and hatch spacing. These parameters affect the temperature, cooling rate, and density of the metal, which in turn influence the microstructure, mechanical properties, and surface finish of the part.

2 DMLS material properties

The material properties of DMLS parts are determined by the type and composition of the metal powder, as well as the process parameters. Density, strength, hardness, and ductility are key properties to consider. Density can be increased through finer powder, higher laser power, and smaller hatch spacing. Strength is improved by stronger alloys, higher laser power, and lower scan speed. Hardness is enhanced by harder alloys, higher laser power, and lower scan speed. Ductility can be increased with softer alloys, lower laser power, and higher scan speed. Tests such as tensile, compressive, shear, fatigue, Rockwell, Vickers, or Brinell can be used to measure these properties. Reporting and documenting the results of these tests is essential for informing stakeholders and improving cloud security posture.

3 DMLS material selection

When selecting a material for DMLS, you should consider its compatibility with the DMLS process and laser parameters, its availability in powder form, and its application for the intended use and performance of the part. For instance, some materials may require special preheating or post-processing to avoid oxidation, cracking, or distortion. Additionally, some materials may be scarce, expensive, or restricted due to environmental or safety regulations. Furthermore, some materials may have specific advantages for certain industries or environments, such as high corrosion resistance, thermal conductivity, or biocompatibility.

4 Common DMLS materials

DMLS can be used with a variety of metals, such as stainless steel, titanium, aluminum, and Inconel. Stainless steel is a versatile option that offers good corrosion resistance, strength, hardness, and ductility. Titanium is lightweight and strong with excellent biocompatibility, corrosion resistance, and fatigue resistance. Aluminum is a low-density material with high conductivity, ductility, machinability, and surface finish. Inconel is a high-performance alloy with exceptional resistance to high temperatures, oxidation, and corrosion. These metals can be used for applications such as medical devices, aerospace components, consumer products, implants, dental crowns, turbine blades, heat sinks, antennas, housings, jet engines, rocket nozzles, or nuclear reactors.

5 Tips and best practices

To achieve the best results with DMLS, it is essential to design for the process and material properties, choose the right parameters, and test and validate. This means avoiding sharp angles, thin walls, overhangs, or internal cavities that may cause stress concentration, warping, or support issues. Experimenting with different laser parameters and settings to find the optimal combination for your material and part is recommended. Quality control and testing should be done on your DMLS parts to verify their dimensions, properties, and performance. Make sure to compare them with your design specifications and expectations.