Selective laser melting

Laser melting offers designers the opportunity to think in completely new directions. In contrast to conventional mechanical production techniques for metal components, such as turning or milling, the additive manufacturing process provides virtually unlimited design freedom. Due to the layered build-up of the metal components, even highly complex geometries can be produced, for example with undercuts or cavities. Without clamping devices or molding tools, the process allows the production of sophisticated components that could not be realized with conventional techniques or only with enormous effort. Designers can thus concentrate fully on achieving functional goals and optimally exploit innovation potential.

Integrate internal functions and structures

One of the design options in laser melting is the simple integration of functional elements, such as internal channels for conformal cooling. In addition, by means of integral construction, individual components can already be connected to one another during the production process. Subsequent processing and assembly costs can be reduced to a minimum. Finally, lightweight constructions also benefit from the laser melting technique, since significant weight reductions can be achieved by introducing hollow portions or honeycomb structures whilst maintaining high stability and functionality.

Versatile in the application

These constructive margins make laser melting an interesting production technology for a variety of applications. These include, for example, the automotive industry, aerospace, medical technology, and in general all applications in which lightweight construction and bionic structures are required.

The potential of laser melting is no longer being applied solely for rapid prototyping. The produced parts meet high material requirements, such as very good thermal resistance and mechanical strength, and can be produced ready for challenging tasks. Rapid manufacturing and rapid tooling are therefore among the possible fields of application, as is the production of small batches or individual components. Due to the low use of materials and tools, cost-effective production is already available from batch sizes of one upwards. If required, the manufacturing technology can be combined with conventional production processes so that finishing work such as surface treatment, welding, milling or eroding can be easily added.

Technical information

• Wall thicknesses from 0.3 mm
• Layer thickness 20 μm, 40 μm, 50 μm
• Surface roughness: Ra 2.5 - 8 μm / Rz 15 - 50 μm
• Hardness up to 52 HRC (hardening process)
• Components up to 250 mm x 250 mm x 310 mm can be manufactured in one piece
• Tolerances: +/- 0,7 %, min. 0,1 mm

Limitations

• Slightly rough surface
• Surface treatment for injection molds and the like is necessary

SLM-manufactured tool inserts increase component quality by

• Reducing distortion
• Reducing sink marks
• Reducing cycle time by an average of approximately 30% and more