The Step-by-Step 3D Printing Process

What Is Sintered 3D Printing?
Sintered 3D printing, also commonly referred to as Direct Metal Laser Sintering (DMLS), is a metal-additive manufacturing process. Laser technology is used in sintered 3D metal fabrication to scan and selectively fuse metal powder particles. The selective fusing bonds the particles together during these processes to build metal parts layer by layer. The powder used in DMLS 3D metal fabrication is made of metal alloys with varying melting points that can fuse at certain elevated temperatures on a molecular level. Metal 3D Printing Steps Explained

The 3D metal printing process starts with a 3D CAD model of a part design. This can be anything from an air intake for a race car to a highly intricate part to be used in a metal watch – the design is up to you. Unlike polymer powder bed fusion processes, 3D-printed structural parts are attached to the sintering furnace through support structures. Support structures are built from the same materials as the parts and help mitigate any possible warping or distortion in the high-process temperatures.
The basic fabrication process for creating 3D-printed structural parts is as follows:

The CAD model is digitally separated into layers. To support the 3D printing manufacturing process, any required support structures are added simultaneously. 2. The powder bed is filled with a high-strength alloy. Generally, this high-strength alloy will be one of the following materials: aluminum, titanium, Inconel, stainless steel or cobalt chrome. A thin layer of the selected alloy is then distributed across the build platform.

1. From there, the build begins. A high-powered laser draws the bottom layer of the batch, along with any temporary support structures necessary to support the 3D printing sintering.
2. A rubber wiper will then scrape another layer of metal powder across the parts, and the lasering process is repeated again and again until completion.
3. Once complete, the part is removed from the build chamber along with the build supports. The 3D-printed structural parts may then be further processed per customer requests.
   After the 3D printing manufacturing process is complete, the parts will be fully encapsulated in metal powder. Once the bin cools to room temperature, the excess powder can be manually removed. From there, the parts will be ready for post-processing. Post-processing treatments can include heat treatment and detachment from the build plate via cutting, machining, hot isostatic pressing or solution annealing. 3D-Printed Structural Parts – Application & Uses
   The possibilities of 3D metal printing processes have made the technology extremely popular in manufacturing complex parts using high-performance metals and alloys. The aerospace, dental, and medical sectors stand to gain the most from sintered 3D printing. These industries often require parts made from high-performance or exotic materials that cannot be manufactured with conventional metalworking technology.
   Medicine
   Custom prosthetics and customized implants can be modeled and printed, with 3D-printed structural parts made from titanium alloys replacing small portions of bone lost to accident or disease. Parts are strong, resistant to body attacks inside, and sufficiently porous that bone can quickly grow into the prosthetic structure thanks to the 3D metal printing process. Additionally, every patient’s prosthetic is distinctive. Dentistry
   Sintered 3D printing can make dental implants, prosthetics, bridges, crowns and partial dentures. These can be easily modeled to a specific patient and fabricated from high-strength materials. The 3D metal printing process can quickly deliver custom-fit, high-strength, durable parts to patients.
   Aerospace
   3D metal fabrication can create parts that are vital in commercial aircraft and rockets, from brackets to highly complex turbine parts. With the 3D metal printing process, scientists can even produce complete rocket exhaust systems. The possibilities only continue to grow.
   Speak to Sentro Tech About 3D Metal Fabrication Today
   Now that you know more about metal 3D printing steps and processes, it’s time to put them into practice in your own laboratory or production facility. Custom-built or standard sintering furnaces from Sentro Tech offer a wide range of capabilities to meet your specific needs. With quick heat-up and cooldown, temperature accuracy and uniformity, customizable temperature ranges and dimensions and much more, sintering furnaces from Sentro Tech are the smartest way to achieve your 3D printing manufacturing processes. View our entire selection and request a quote today. Or, if you have any questions, please contact us at any time. Our knowledgeable staff is prepared to assist.