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Metal printing via selective laser melting produces impressive results
The history of selective laser melting began around 1995, with the Aachen-based Fraunhofer Institute for Laser Technology ILT playing a leading role as a pioneer of this innovative metal processing technology.
In selective laser sintering, the metal, which is in powder form, is applied as a thin layer (approx. 30 – 50 μm) to a substrate plate (= printing plate), where it is melted locally using a laser beam. The structures specified in the CAD files are built up precisely in such a way that the cooling metal powder solidifies in exactly the desired shape. In this way, the desired 3D model is built up layer by layer. To protect against unwanted chemical reactions, selective laser melting usually takes place under a protective gas atmosphere of argon or nitrogen.
In principle, the selective laser melting, also known as the SLM process, works no differently than the selective laser sintering (which is well known and widely used from the 3D printing processing of PA plastics), with the difference, of course, that the powder in the SLM printing process not sintered will.
Unlike SLS printing, the metal powder is completely melted in the SLM process, which means that a higher temperature is required than for SLS printing processes. Of course, this also means that the printed parts need more time to cool down.
3 important advantages of selective laser melting
One of the biggest advantages of selective laser melting is 1.) the freedom of geometry, i.e. the possible production of complex, filigree structures that would never be possible in this form with conventional manufacturing processes. These include undercuts, such as can occur in jewelery and design models as well as in technical components, but also open-pored structures, which can be realized in light components in particular thanks to SLM printing while maintaining strength at the same time.
In the case of components manufactured using a mixed or hybrid construction method (i.e. components that are only partially generatively manufactured), 2.) another advantage of SLM 3D printing is that the construction volume to be manufactured using this metal printing technology can be greatly reduced.
In addition, selective laser melting 3.) – like other 3D printing processes – enables samples and prototypes to be produced promptly, whereby highly individualized individual parts can also be implemented at an economically justifiable expense.
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