Challenges in Direct Metal Printing: controlling process and part quality

Metal Additive Manufacturing (AM) is now becoming a maturing production technique. 3D Systems’ solutions to allow precision production in this new field are including ProX®  Direct Metal Printing (DMP) printer series (a laser based powder bed fusion process), LaserForm® materials and a all in one software solution 3DXpertTM software.

In this presentation, first, the metal AM portfolio and activities at 3D Systems will be briefly introduced. Our activities not only include the development of these productis, but also a complete solution for prototyping as well as serial production service to customers. Our strong involvement in both the technology development as well as intensive usage allows us to build up knowledge and implement solutions very fast.

In the second part of the presentation, a closer look is given to the metal AM process. Given the numerous physical phenomena taking place and the strict quality requirements that are put by the high end markets, the process is not just a push the button production technique. Furthermore, the shape of the product and the materials properties are generated at the same time and can come in conflict. Some examples of typical process difficulties and part properties will be presented.

Finally, an outlook to the future and how software solutions will play an important role in developing new materials, controlling (local) part dimensions and properties and ensuring part quality will be discussed.