4 design rules to get started quickly in 3D metal printing
3D metal printing provides benefits in both the production process and the end product. One condition is that the design takes into account the specific characteristics of the laser melting process. If you follow a number of simple design rules, you can quickly make prototypes and low volume production with 3D metal printing.
With 3D metal printers such as the XM200C from Xact Metal , 3D metal printing no longer requires extremely high investments. For less than a solid 3-axis CNC machining center, you can start metal printing with this laser powder bed machine. This allows you to print complex parts in materials such as 316L, aluminum, cobalt chrome, Inconel 625 and Hasteloy, titanium and bronze and copper.
Aspect ratio
To maximize the benefits of 3D metal printing, there are some design rules. One of these is that the height-width ratio affects the end result. As a rule of thumb, use a ratio of 8:1 to reliably 3D print narrow features. Otherwise there is a risk of damage to the recoater when it applies a new powder layer. The minimum wall thickness is 100 to 200 micrometers, depending on the material.
Avoiding support structures is the best solution
Overhanging parts
The most Metal Powderbed Fusion 3D printers can 3D print overhanging parts provided the angle is greater than 45 degrees. If a smaller angle is required, a support structure must certainly be installed below 30 degrees. An angle between 30 and 45 degrees can be 3D printed without support, but the bottom of the product will then be rougher than the rest. Support structures can be printed well, but it is better to avoid them. This not only saves material costs but also time in post-processing when they have to be removed again.
Holes
The rules of thumb for printing holes are for metal printers, such as the completely new one XM300C (with 4 lasers and a construction volume of 245 by 330 by 330 mm), holes smaller than 5 millimeters can be printed without any problems. Larger round holes require an internal support structure. This must be taken into account in the design, because this structure must be removed mechanically afterwards. If that is not possible, you may want to consider adjusting the shape of the hole. An oval or drop-shaped hole can be 3D printed without support.
Remove powder
During the build job of an Xact Metal powder bed metal printer, the entire build chamber is filled layer by layer powder . This means that all hollow parts are filled with powder when the workpiece is finished. So take into account in the design that this powder must be able to be removed. A hole intended for this must have a minimum diameter of 3 millimeters. For larger volumes it is advisable to include multiple holes in the design, which speeds up the post-processing of the workpiece.
Seido Systems supplies the Xact Metal XM200C 3D metal printer including all necessary personal protective equipment and training for a very competitive price. With this we ensure that 3D metal printing is accessible to every metal company. Curious? Ask it one of our sales staff.
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