New innovations in Direct Metal Laser Sintering process -: A step forward in rapid prototyping and manufacturing

Direct Metal Laser Sintering (DMLS) is a laser-based rapid tooling process developed in Europe by Electrolux Rapid Development Finland and EOS GmbH Germany. Electrolux Rapid Development pioneered also in the commercial implementation of this rapid tooling technique for functional prototyping. Basic principle of the DMLS is to fabricate net shape metal parts directly in one single process. This is achieved by using laser sintering machine equipped with a high power laser, precise optics, scanner and automatic process control. The superior accuracy of sintered metal parts is achieved by suppressing the shrinkage problems with special material selection. Continuous research and development work in the field of new materials for the DMLS-process has recently resulted in tailored steel based powder blend with highly improved material properties and excellent accuracy. The effects of the new powder material, improved scanning strategies and reduced layer thickness are presented. In addition, most important new application areas such as rapid tooling for die casting and direct metal component manufacturing are introduced. Capability of the DMLS-process in manufacturing 3D-shapes with great complexity is also presented with case studies.