Metal 3D printing

What is metal 3D printing? At Star, we use a 3D printing process called Direct Metal Laser Melting (DMLM). This additive manufacturing process uses high-powered lasers to melt and fuse successive layers of powdered metal into three-dimensional solid parts. The advantage is that the more complex or feature-rich the components, the more economical the process. Benefits of 3D Printing There are many benefits to 3D printing, especially if you know how to optimize your product design to take advantage of them. Benefits include: Metal 3D printed parts are fully dense and contain complex geometries and precise internal features that cannot be manufactured using traditional machining alone. Designs can be made quickly with minimal waste of material while maximizing strength. Conformal cooling channels greatly improve performance and resistance to thermal stress, ideal for aerospace and automotive applications. Multiple identical parts can be built on one platform at the same time, greatly improving production efficiency. Metal 3D printing process First, a 3D CAD file must be provided for the design. For best results, our engineers must check your CAD drawing files in advance and optimize the design if necessary. This can include optimizing build orientation and adding support structures to areas where gravity may cause features to distort during printing. These support will be removed later. We then used specialized software to cut the drawings into multiple cross-sectional layers, each layer representing a 20-60 μm thickness of the final shape. Finally, we upload the slice file to the machine to be printed. At Star we use the Renishaw AM250, an advanced metal 3D printer for rapid prototyping and fabrication. Metal 3D printing tolerances The general tolerance for metal 3D printing is +/- 0.5mm. However, it depends significantly on the geometry of the part being printed. Check out more guidelines to follow when designing for metal 3D printing. Metal 3D printing materials We currently offer 3D metal printing in titanium, stainless steel, maraging steel and aluminum. Each material offers unique advantages related to mechanical properties, weight, corrosion resistance, and more. Economic costs also need to be considered, so our engineers are happy to advise on the best material for your application and budget. Post-processing services Metal 3D printing almost always requires some form of post-processing to provide functionality that 3D printing alone cannot. Use our in-house AddSub® service, a quick and easy process to remove material via CNC milling and turning, drilling or grinding. We also have a range of other finishing processes to ensure you get the final look you want.