3d metal printing

DEPARTMENT OF MECHANICAL ENGINEERING
A Seminar on
3D – METAL PRINTING
(ADDITIVE MANUFACTURING)
8-Apr-21 ME451_Seminar/Project_2016-2020 Batch 1

OUTLINE OF PRESENTATION
 Introduction
 Types of 3d metal printing
 Working of 3d metal printing machine
 Printer parameters
 Advantages
 Disadvantages
 Applications
 Conclusion
 Reference

INTRODUCTION
1984, Charles Hull - stereolithography.

 3d metal printing was developed from stereolithography.
Fig1-steriolithography
8-Apr-21 3
ME451_Seminar/Project_2016-2020 Batch

WHAT IS 3D METAL PRINTING?
Metal 3d printing is also known as additive manufacturing,
it’s a process in which the parts are manufactured by a high energy
laser melting and bonding the metal powder particles layer by
layer.
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 Layer by layer manufacturing process
 Build dense metallic parts with high precision
 Additive manufacturing or digital manufacturing,
free form fabrication, or 3d printing.
 potential to reduce cost, energy consumption, carbon footprint.
 Common software's used
• infiAM Central
• infiAM Spectral
• QuantAM
• Magics
Ref [1],[3]

TYPES OF 3D METAL PRINTING.
There are two types of 3d metal printing:
 Selective Laser Melting (SLM)
 Direct Metal Laser Sintering (DMLS)
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SELECTIVE LASER MELTING (SLM)
SLM uses metal powders with a single melting temperature and
fully melts the particles.
 High rate of homogeneity
Take much lesser time for manufacturing.
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Fig 2- 3d metal printing.

DIRECT METAL LASER SINTERING
(DMLS)
 DMLS the powder is composed of materials with variable
melting points that fuse on a molecular level at elevated
temperatures.
 Desired properties can be achieved easily.
 Takes more time to manufacture as the melting point lies on a
range of temperature instead of a point.
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WORKING OF 3D METAL PRINTING
MACHINE
 Build chamber is filled with inert gas (Ar) to minimize the oxidation
 Metal powder is heated to the optimal build temperature.
 A thin layer of metal powder is spread over the build platform
 laser scans the cross-section of the component, melting the metal
particles together.
 After scanning, the build platform moves downwards by one layer
thickness and the rollers spreads another layer of metal powder.
 The process is repeated until the whole part is complete.
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p
Fig 3- 3d metal printing process.

PRINTER PARAMETERS
The layer height used in metal 3D printing varies between 20
to 50 microns (flowability, particle size distribution, shape of
the particle, etc).
The typical build size of a metal 3D printing system is 250 x
150 x 150 mm, larger machines - (up to 500 x 280 x 360 mm).
Dimensionally accuracy - approximately ± 0.1 mm.
The metal powder in SLM and DMLS is highly recyclable:
typically less than 5% is wasted.(support material)
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NEED FOR SUPPORT STRUCTURE
Parts are oriented in angle to reduce warping.
Support in metal 3D printing serves 3 different functions:
They offer a suitable platform for the next layer to be built upon.
They anchor the part to the build plate and they prevent warping.
They act as a heat sink drawing heat away from the part and
allowing it to cool at a more controlled rate.
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COMMON METAL POWDERS
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ADVANTAGES
Metal 3D printing processes can be used to manufacture
complex, bespoke parts with tough geometries.
Metal 3D printed parts can be topologically optimized to
maximize their performance while minimizing their weight and
the total number of components in an assembly.
Metal 3D printed parts have excellent physical properties and the
available material range includes difficult to process otherwise
materials, such as metal superalloys.

DISADVANTAGES
The material and manufacturing costs connected with metal 3D
printing is high, so these technologies are not suitable for parts
that can be easily manufactured with traditional methods.
The build size of the metal 3D printing systems is limited, as
precise manufacturing conditions and process control are
required.
Already existing designs may not be suitable for metal 3D
printing and may need to be altered.
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APPLICATIONS
 Aircraft frames
 Jet engine parts
 Oil and gas equipments
 Ballistic material
 Semiconductor manufacturing
 Marine propulsion
 Nuclear components
Ref [1]

CONCLUSION
 Metal 3D printing is most suitable for complex, bespoke parts that are
difficult or very costly to manufacture with traditional methods.
 Minimizing the need for support structures will greatly reduce the cost
of metal printing.
 Topology optimization is essential for maximizing the added benefits of
using metal printing.
 Metal 3D printed parts have excellent mechanical properties and can be
manufactured from a wide range of engineering materials, including
metal superalloys.
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REFERENCE
[1] Thomas Duda, L. Venkat Raghavan, “3D Metal Printing
Technology” IFAC (International Federation of Automatic
Control), 2016, 2405-8963
[2] Dr. O.P.Gupta, “Metal 3D Printing-State of Art Review and
Guidelines”, Aug 2014,
[3] William E. Frazier,“Metal Additive Manufacturing: A Review” ,
(Submitted February 24, 2014; published April 8, 2014)

THANK YOU

3d metal printing

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