SLM process: reliable and reproducible

Stakeholders from a wide range of disciplines have long been researching technical and process-related solutions that will enable a further leap forward in the development of additive manufacturing. Studies show that component and material defects are primarily caused by machines, materials and faulty processes. In addition to geometric deviations, insufficient surface quality, bonding errors and porosity have been identified as problems. Typical defects also include process interruptions, which then lead to waste and rejects. With this in mind, DMG Mori has revised the Lasertec 30 SLM series and deliberately labeled this development leap with the eponymous attribute "3rd generation".

The most important thing for industrial manufacturers: The 3rd generation Lasertec 30 SLM ensures machine comparability for the first time. "The basis for this are technical innovations that are based on experience in machine tool construction and with which DMG Mori ensures very high process stability," says Jan Riewenherm, Head of Technical Sales & Marketing at DMG Mori Additive. This should be of particular interest to companies that have struggled with fluctuating component quality in series production up to now. The Lasertec 30 SLM 3rd generation is a technical solution for all industries that have very high demands on component quality.

With experience with lathes and milling machines

Years ago, immense growth was predicted for additive manufacturing. To this day, the aforementioned problems are the reason why the number of applications on the market is lagging behind forecasts. In the first two generations, DMG Mori concentrated on the optimum process design for laser melting. When developing the 3rd generation, the engineers focused entirely on the experience gained from decades of developing turning and milling machines. The goal: comparability of components. To this day, industrial manufacturers have the problem that even components from identical machines can have different qualities. These factors have made laser melting economically unattractive for global companies with several production sites, for example - despite all the other advantages of additive manufacturing.

Additive manufacturing in small or large series

The Lasertec 30 SLM solves many of these problems and lowers the barriers to entry. Users can now utilize additive manufacturing in small or large series. DMG Mori has also designed the new Lasertec with a cast frame and a so-called floating process chamber, drawing on its experience in turning and milling machine construction. The process chamber is floatingly mounted in the cast frame and can expand freely in the event of temperature fluctuations. This minimizes thermally induced distortion. The casting frame and floating process chamber are therefore key elements for a firmly defined machine condition. Whether the machine is cold-started on Mondays or preheated - the component qualities are now identical in series production. The optical modules are permanently mounted on the casting frame. Precise calibration of the coater using a reference surface ensures a constant distance between the optics and the powder bed, additionally supported by active temperature compensation of the positioning in the Z-axis. This also ensures reproducible component quality.

Constant component qualities and powder quality correlate. Oxidation, cross-contamination between different materials and moisture ingress must therefore be avoided. With this in mind, DMG Mori has developed the RePlug system, which has already proven its worth in previous machines. The module works in a closed circuit under an inert gas atmosphere and thus reduces the aforementioned risks to a minimum. Unmelted powder is automatically sieved off and reused. If different components made of different materials are to be produced on a Lasertec 30 SLM 3rd generation, this can be done quickly and easily by changing the RePlug powder module. Replacing the entire powder management module reduces the cleaning effort to just a few components. The closed powder circuit ensures the highest possible level of work safety for the operator, as direct contact with the powder is reduced to an absolute minimum. The machine has an interchangeable construction container to ensure the shortest possible set-up times. It guarantees a quick changeover between the finished construction job and a new job while fully maintaining the inert gas level, both in the process chamber and in the construction container itself. All in all, factors that promote work safety and productivity in equal measure.

Benefit from more design freedom

"The Lasertec 30 SLM 3rd generation not only ensures machine comparability, but also process stability," says Jan Riewenherm. With additive manufacturing, companies benefit from the design freedom that the technology brings. There are also opportunities for volume reduction and structural optimization. Consistent component qualities also make the manufacturing process interesting for companies with larger batches. New users also benefit from an easier introduction to the technology. Against this backdrop, the Lasertec 30 SLM 3rd generation paves the way for the continued triumph of additive manufacturing.

Formnext, Hall 12.0, Stand D139

DMG Mori, en.dmgmori.com