Aditivní výroba SLM

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Přehled o Aditivní výroba SLM

Selective laser melting (SLM) is an additive manufacturing technology that uses a laser to selectively melt and fuse metallic powder material layer by layer to build up 3D objects. SLM is suited for processing reactive metals like titanium, aluminum, and stainless steel into fully dense and functional parts with complex geometries.

SLM offers several benefits compared to traditional manufacturing:

Benefits of SLM Additive Manufacturing

BenefitPopis
Svoboda designuSLM can produce complex geometries like lattices, internal channels, and organic shapes not possible with machining
PřizpůsobeníParts can be easily customized and optimized for function rather than manufacturability constraints
OdlehčeníOrganic shapes and lattices allow parts to be lightweight while retaining strength
Úspora materiáluSLM only uses the required amount of material versus machining from solid blocks
Fast prototypingParts can be directly 3D printed from CAD vs. tooling for prototyping
Výroba Just-in-timeOn-demand printing as needed reduces inventory costs
Supply chain resilienceDistributed manufacturing reduces supply chain risks

However, SLM also comes with some limitations:

Limitations of SLM Additive Manufacturing

OmezeníPopis
Náklady na strojIndustrial SLM machines have high upfront capital costs of $100K-$1M+
Možnosti materiáluCurrently limited to reactive metals like titanium, aluminum, tool steels, and superalloys
PřesnostTypical accuracy of 0.1-0.2mm is lower than machining tolerances
Povrchová úpravaAs-printed surface is rough and requires post-processing
Velikost stavbyMaximum part size is restricted by printer chamber size
Low batch productionMost economical for small batch and custom parts vs. mass production
Následné zpracováníAdditional steps like supports removal, heat treatment required

Jak funguje 3D tisk SLM

SLM is an powder bed fusion technology that uses a focused laser beam to selectively melt and fuse metallic powder material layer by layer.

The key steps in the SLM process are:

SLM 3D Printing Process

KrokPopis
3D modelA 3D CAD model is digitally sliced into layers
Spread PowderA recoater blade spreads a thin layer of powder across the build platform
Tavení laseremA laser beam traces each layer melting powder to bond it based on the sliced CAD data
Lower PlatformThe build platform lowers and another layer of powder is spread on top
Opakování krokůThe layer melting process is repeated until the full part is built up
Remove PartThe completed 3D printed part is removed from the powder bed
Post-ProcessThe part is cleaned and heat treated to relieve stresses

Materiály SLM

SLM is capable of processing a range of reactive metals into fully dense parts including:

Materiály SLM

MateriálKlíčové vlastnostiAplikace
Titanové slitinyVysoký poměr pevnosti a hmotnosti, biokompatibilitaLetectví a kosmonautika, lékařské implantáty
Hliníkové slitinyLehké, vysoce pevnéAutomobilový a letecký průmysl
Nerezové oceliOdolnost proti korozi, vysoká pevnostIndustrial tooling, marine
Nástrojové oceliVysoká tvrdost, tepelná odolnostVstřikovací formy, zápustky
Niklové superslitinyOdolnost proti teplu a koroziLopatky turbín, trysky raket
Kobalt ChromeOdolnost proti opotřebení, biokompatibilitaDental implants, orthopedics

The most common SLM materials are titanium and aluminum alloys, along with tool steels and stainless steels. More exotic superalloys and metal composites can also be processed with SLM technology.

Pokyny pro navrhování SLM

To successfully design parts for SLM 3D printing, engineers should follow these guidelines:

Pokyny pro navrhování SLM

PokynPopis
Avoid overhangsMinimize overhangs requiring supports which must be removed
Design anchorsInclude small anchors or tabs to secure the part to the build plate
Orientujte se na síluAlign the part to maximize strength in functional direction
Minimize part heightOrient to minimize Z-height to avoid collapsing delicate features
Allow for post-machiningAdd 0.1-0.3mm allowance for post-processing if tight tolerances needed
Optimize lattice designsTune cell size and strut size to part loads and SLM constraints
Include vent holesAdd small holes to prevent trapped powder causing defects
Konformní chladicí kanályDesign complex internal cooling channels not possible with drilling/machining
Combine partsConsolidate assemblies into single parts to reduce assembly requirements

Following these guidelines helps avoid common SLM print defects like poor surface finish, distortion, cracking, or trapped powder.

Výrobci tiskáren SLM

The major SLM system manufacturers include:

SLM 3D Printer Manufacturers

SpolečnostPrintersKlíčové vlastnosti
EOSEOS M290, EOS M300 x4Pioneer of metal 3D printing, excellent part properties
Řešení SLMSLM 280, SLM 500, SLM 800Very high laser power for productivity, large build volumes
3D SystemsDMP Factory 500Scalable systems for high volume production
Přísady GEConcept Laser M2, X Line 2000RNow part of GE, reliable productivity workhorses
RenishawRenAM 500QExcellent precision, integrated Quality Management System

In choosing an SLM system, key factors are build volume, laser power, materials capabilities, precision, and software workflow. The leading manufacturers offer established systems, but many new entrants from China and India are also emerging.

SLM Printer Pricing

Industrial SLM systems have high upfront capital costs ranging from $100,000 for entry-level machines upto $1,000,000+ for high-end production systems:

SLM Printer Pricing

VýrobceModel tiskárnyObjem sestaveníCenové rozpětí
EOSEOS M10095 x 95 x 95 mm$100k – $150k
Řešení SLMSLM 125125 x 125 x 125 mm$175k – $250k
3D SystemsDMP Factory 500500 x 500 x 500 mm$500k - $800k
Přísady GEConcept Laser M2 Series 5250 x 250 x 280 mm$700k – $900k
RenishawRenAM 500M250 x 250 x 350 mm$950k – $1.2M

Larger build volumes, higher laser power, and productivity features drive up system costs. But choosing wisely based on application needs and production requirements is key.

SLM Facility Considerations

To operate an SLM facility successfully, businesses should consider:

SLM Facility Factors

FaktorPopis
Facility CostsAccount for printer, materials, and facility buildout costs
Material HandlingInstall powder handling equipment and provide PPE for workers
Následné zpracováníCleaning equipment, heat treatment, HIP, surface finishing etc.
SoftwareWorkflow software for scheduling, nesting, process monitoring
ŠkoleníTrain engineers on design and technicians on printer operation
BezpečnostFollow powder handling procedures and have fire suppression systems
ÚdržbaSchedule regular system maintenance and calibration
Kontrola kvalityMeasure dimensions and material properties, repeatability testing
CertifikaceISO 9001, AS9100 certification for regulated industries

Choosing an experienced service provider can help navigate facility setup, operations, and certification for regulated applications like aerospace or medical devices.

slm additive manufacturing

Výhody aditivní výroby SLM

The key advantages of SLM 3D printing include:

SLM Additive Manufacturing Advantages

VýhodaPopis
Složité geometrieSLM can produce highly complex organic shapes and intricate internal lattices and channels
Customized PartsEasily create customized parts tailored to customer needs versus tooling constraints
Snížení hmotnostiLattice structures and topology optimization enables lightweight, strong designs
Consolidated AssembliesCombine multiple components into single complex parts
Fast Lead TimesPrint parts on-demand directly from CAD data versus months for machining
Snížení množství odpaduOnly use required amount of material versus machining from billet
Výroba na vyžádáníEnables distributed just-in-time manufacturing close to customers
Inventory ReductionPrint parts as needed reducing tooling, warehousing, inventory costs
High-Performance MaterialsProcess advanced metals like titanium and superalloys into end-use parts

The design freedom, part customization, and distributed production capabilities make SLM ideal for low to medium volume production for aerospace, medical, industrial, and automotive applications.

Limitations of SLM Additive Manufacturing

SLM does have some limitations including:

SLM Additive Manufacturing Limitations

OmezeníPopis
Machine CostSLM printers have high capital costs often over $500,000
Material AvailabilityCurrently limited to reactive structural metals versus plastics
PřesnostTypical accuracy of 0.1-0.2mm is lower than CNC machining
Povrchová úpravaAs-printed surface is relatively rough with stair-stepping effect
Následné zpracováníSupport removal, machining, polishing often required
Print SpeedBuild rates typically 5-100 cc/hr limit speed versus mass production
Max Part SizeLimited by printer build volume, typically under 500 x 500 x 500 mm
Process MonitoringLack of in-situ monitoring can lead to undetected defects
Operator ExpertiseSLM technicians require significant training on procedures
Náklady na materiálPowder metals can be 2-5x more expensive than raw stock

For very high accuracy needs, extremely large parts, or mass production volumes, subtractive methods like CNC machining tend to be more suitable than SLM additive.

The Role of SLM in Manufacturing

SLM is best suited for:

Best Roles for SLM in Manufacturing

Manufacturing RolePříklady
Rychlé prototypováníFast design iterations and proof-of-concept parts
Low-volume productionAerospace brackets, impellers, medical implants
Bridge toolingProducing early units while injection molds are made
Konsolidace částiCombining multiple components into single parts
Hromadné přizpůsobeníCustomized end-use products like dental aligners
Distributed manufacturingOn-demand local production close to customers

For very high volumes, conventional high-pressure die casting or plastic injection molding tend to be more cost-effective than SLM 3D printing. But for short run production, SLM excels.

The Future of SLM Additive Manufacturing

SLM is expected to expand into wider applications in the future through:

Budoucnost SLM

TrendPopis
Larger printersBuild volumes over 1 meter length and height
Multi laser systemsHigher power multi-laser machines over 1 kW
Faster speedsPrint speeds up to 500 cc/hr via scanned galvo lasers
New materialsHigh temperature alloys, MMCs, novel composites
Hybrid manufacturingCombined AM and subtractive processes in one system
Automated post-processingReduced manual labor for support removal, surface finishing
In-process monitoringIn-situ monitoring of melt pool, powder bed, and part defects
SimulationPhysics-based simulations to predict behavior and optimize builds
Machine learningAI for design, process optimization, quality assurance
Digital supply chainSeamless digital workflow from design to production

Choosing an SLM Service Provider

When selecting an SLM service provider, buyers should evaluate:

Choosing an SLM Service Provider

FaktorPopis
Printing EquipmentLook for reputable industrial metal printers with high beam power and large build volumes
MateriályAbility to process desired alloys like titanium, tool steel, stainless steel
Následné zpracováníOffer full range of post-print processing like HIP, machining, polishing
Quality ProceduresISO 9001 or AS9100 certified with strict QA processes
Application ExperienceExpertise and case studies in target applications like aerospace, automotive, medical
Design SupportCapability to design and optimize parts for AM manufacturability
Předběžné časyAbility to deliver sample and production parts within required timeframes
File PreparationAccept standard CAD and polygon file formats with design analysis
Post Build ServicesCleaning, heat treat, surface finishing, coating services
Další službyInspection, rapid prototyping, bridge tooling, castings, molding
Stanovení cenCompetitive and scalable pricing for different build volumes
UmístěníProximity for supply chain logistics and communication

Choosing a service provider with end-to-end capabilities from design to post-processing ensures high quality results. Checking case studies and visiting facilities helps verify experience.

slm additive manufacturing

Nejčastější dotazy

Q: What materials can be 3D printed with SLM technology?

A: SLM is capable of processing a range of reactive metals like stainless steel, tool steel, titanium alloys, nickel superalloys, aluminum alloys, and cobalt chrome. The most popular SLM materials are titanium Ti6Al4V and AlSi10Mg aluminum.

Q: How accurate is SLM 3D printing?

A: SLM typically produces accuracy around 0.1-0.2mm. While lower than CNC machining tolerance, post-processing like machining and polishing can improve accuracy. Feature sizes below 0.3mm are not recommended.

Q: What industries use SLM additive manufacturing?

A: Aerospace, medical, dental, automotive, and industrial sectors are major users of SLM technology today due to benefits like lightweighting, part consolidation, mass customization, and rapid turnaround times.

Q: What post-processing is required after SLM printing?

A: Common post-printing processing includes support removal, stress relieving heat treatment, Hot Isostatic Pressing (HIP), CNC machining, polishing, and coating. The requirements depend on application, material, and finish needs.

Q: How expensive is SLM metal 3D printing?

A: Industrial SLM systems range from $100,000 to over $1 million depending on build volume, laser power, and features. Material costs for metal powder can be 2 to 5 times the cost of raw stock. But total costs are coming down.

Q: Can SLM print overhangs and complex shapes?

A: Yes, SLM can print geometries like overhangs, lattices, and thin walls through the use of support structures. Careful orientation is needed to avoid deformation and balance support requirements.

Q: What software is used for SLM printing?

A: SLM printers come with proprietary software for printing. Additional software is used for design, file repair, simulation, build preparation, nesting, build management, and quality management.

Q: How long does it take to 3D print a part with SLM?

A: Print times range from hours to days depending on the part size, geometry complexity, and print parameters. For metal parts, SLM printers typically operate from 5 to 100 cc/hour build rate. Larger parts take longer.

Q: Does SLM produce safe and functional end-use metal parts?

A: Yes, with proper design and processing, SLM can produce fully dense metal parts meeting or exceeding material properties of traditionally manufactured parts for functional end-use in demanding applications.

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