Disadvantages of laser printing of metal parts

Additive 3D laser printing is certainly known for making the impossible possible, but what about accuracy? Is 3D printing a good way to make small, sophisticated metal parts?

Let's take a look at DMLS, the most mature and well-developed method, where the important variables driving dimensional accuracy are:

Size of powder particles

The height interval between elevator steps

Laser beam size

Each of these factors determines dimensional tolerances. The larger metal powder particle size makes the step larger. The height of each powder layer also determines the tolerance that can be achieved.

Perhaps the most important variable is the size of the laser. That's why tiny beams give you more precision, while larger beams give you less precise dimensions. The problem is that a smaller laser beam produces less heat -- which means it takes longer to do its job. So, you can have a very precise and/or very small part, but it takes longer to produce. That, in turn, increases costs.

There are other time-consuming ways of laser printing metals. Look again at the very popular DMLS, where each component has a tiny connection point, like a porch on which the honeycomb hangs. If you have 10,000 laser printed parts, that means you have 10,000 connection points that must be separated. The task of separation from the base is usually done using EDM; But no matter what method you use, doing it 10,000 times will make most additional advantages fail.

The reality is that 3D laser printing of metals is still not ready for true mass production. Which makes the production of tens of thousands of very small also, 3 d printers upfront costs are high: some of the latest desktop needs at least $100000, before the desktop is designed to overturn the disruptors, up to more than $1 million is suitable for the use of titanium metal controlled atmosphere printer or to create a huge aviation parts of the machine shell. The high cost means that whatever application laser printers are proposed will need to "add" something truly unique to "subtract" from the value of traditional metal-making methods.

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