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FAQ’S FOR METAL 3D PRINTING

 

  1. How does Metal 3D Printing work?

 

Metal 3D printing is carried out in 3 steps:

  • The build chamber is first filled with inert gas (for example argon) to minimize the oxidation of the metal powder and then it is heated to the optimal build temperature.

  • A thin layer of metal powder is spread over the build platform and a high power laser scans the cross-section of the component, melting (or fusing) the metal particles together and creating the next layer. The entire area of the model is scanned, so the part is built fully solid.

  • When the scanning process is complete, the build platform moves downwards by one layer thickness and the recoater spreads another thin layer of metal powder. The process is repeated until the whole part is complete.

The part is then broken free of the support structures and finished.

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  2. What is the maximum build size available for metal printing?

 

The typical build size of a metal 3D printing system is 250 x 150 x 150 mm, but larger machines are also available (up to 500 x 280 x 360 mm).

 

  3. What is the accuracy of a metal 3D Printer?

 

The dimensionally accuracy that a metal 3D printer can achieve is approximately ± 0.1 mm.

 

  4. What are the materials available for metal 3D printing?

 

A variety of metals are available in the in powder form for 3D printing. Some of them are:

  • Stainless Steel

  • Aluminium & Aluminium alloys

  • Cobalt-Chromium

  • Titanium & Titanium alloys

  • Super Nickel alloys

  • Inconel

  • Brass

  • Copper

  • Tool Steels

  • Maraging steel

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  5. What are the advantages of Metal 3D printing?

 

  • Metal 3D printing processes be used to manufacture complex, bespoke parts with geometries that traditional manufacturing methods are unable to produce.

  • 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.

 

  6. What are the limitations of Metal 3D printing?

 

  • 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.

 

  7. What are the application areas of Metal 3D printing?

 

3D Printing is touted to be the third industrial revolution and has been around for two decades. The popularity and accessibility of this revolutionary technology is increasing at fast and steady pace. We have empowered clients various verticals such as.

  • Medical

  • Architecture

  • Electronics

  • Education

  • Footwear

  • Automotive

  • Product Design (Prototyping)

  • Tooling

  • Casting and Engineering

  • Customised Gifting (3D Face Scanning)

  • Plastic Moulding and more

 

  8. What is the difference between SLM & DMLS?

 

The differences between SLM and DMLS come down to the fundamentals of the particle bonding process (and also patents): SLM uses metal powders with a single melting temperature and fully melts the particles, while in DMLS the powder is composed of materials with variable melting points that fuse on a molecular level at elevated temperatures.

Essentially, SLM produces parts from a single metal, while DMLS produces parts from metal alloys

 

  9. What is the most time consuming step in Metal 3D Printing?

 

Apart from the actual printing of the part, the most time consuming step in metal 3D printing is the designing phase wherein the part needs to be designed in a CAD software taking into consideration all the parameters which may affect the part during printing. Essentially, DfAM needs to be incorporated in the part at the design stage itself

 

  10. Does Metal 3D printing require support structures?

 

Yes, Metal 3D printing does require the use of support structures.

 

  11. Where can I get a 3D model printed? I don’t want to own a 3d printer.

You can contact us for a quote if you have an already designed model. If not, we also provide designing and scanning services wherein we help you make a model of the product in a CAD software and print the same

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  12. Can I make Moulds & Dies using 3D Printing?

 

Making moulds for jewellery casting, vacuum forming and injection moulding is very possible. We have materials that are well suited for these applications.

 

  13. What is the minimum thickness to print?

 

For the optimum results, we recommend no dimension smaller than 1 mm or 0.039 of an inch.

 

 

  14. What file formats do you accept?

 

We prefer to accept .STL files, as our machines run best using this format. We also accept .OBJ and VRML (.WRL) files. It is best to "save as" or export a .STL file for use in 3D printing.

 

  • .OBJ - .OBJ file is a geometry definition file format similar to .STL and used and developed from the animation industry.

 

  • .STL - .STL is commonly referred to as stereolithography and is widely used for rapid prototyping and computer-aided manufacturing. .STL files describe only the surface geometry of a three-dimensional object without any representation of colour or texture.

 

  • .WRL - .WRL is an extension of the .VRML virtual reality model language file format. It contains the colour and texture maps needed to be printed in relation to the objects 3D surfaces.

 

  15. How much is it going to cost to print my object?

 

Each 3D printed object is unique, and price varies based on material cost, print time as well as finishing. The biggest variable in the final cost is the volume of the printed object. Please contact us for a detailed estimate.

 

  16. What is the turnaround time for prints?

 

Print times vary based on size of the build, material used, and machine.Please contact us for a quote.

 

  17. What is infill in 3D printing?

 

In 3D printing, infill refers to the structure printed inside the object. The size, shape, pattern, and percentage depends heavily on the design requirements. Higher infill percentage translates to physically stronger 3D printed samples.

 

  18. Can different infills be chosen for my objects?

 

Yes, you can opt for different infills for your object. This can be manipulated through different levels in the software. Lower infill percentage can help you to save filament and print time

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