Manufacturers are constantly looking for technology that will allow them to operate more efficiently. One such technology that is reducing costs and lowering lead time for parts is Direct Metal Laser Sintering (DMLS), also known as SLS sintering. Here are a few ways this up-and-coming technology is forever changing the way certain parts are manufactured.

1. What is Direct Metal Laser Sintering?
Manufacturersare constantlylookingfortechnologythatwill allow themtooperate more efficiently.One such
technologythatisreducingcostsand loweringleadtimeforpartsisDirectMetal Laser Sintering (DMLS),alsoknownas
SLS sintering.Here are afewwaysthisup-and-comingtechnologyisforeverchangingthe waycertainpartsare
manufactured.
What is Direct Metal Laser Sintering?
Sinteringisthe processof creatinga solidmassoutof certainmaterialssuchasmetals,ceramics,andmineral deposits.
The Direct Metal Laser Sinteringprocessallowsthistohappenthroughthe use of carefullytargetedlasers,whichshape
and formvariousmetalswithoutcausingthemtobecome liquefiedinthe process.Some commonmaterialsused
include titanium,steel,alloymixtures,polystyrene,andgreensand.Althoughthisprocessisjustnow becoming
widespread,ithasactuallybeenaroundformore than 30 years,andwas firstestablishedatthe Universityof Texasat
Austinduringthe 1980s.
How it Works
Laser sinteringbeginswitha3D Computer-AidedDesign(CAD)model,whichcreatesaunique file andthentransmitsit
to the machine’ssoftware.Thisallowsthe machine operatorto“tweak”the program byaddingsupportstructure and
orientingcertainotherfeaturestocreate a “buildfile.”Once thisbuildfileiscomplete,itisdownloadedandraw
materialsare placedintothe machine.The finishedproductwill thenbe producedinlayerstocreate ahighqualitypart
that containsa great deal of accuracy and attentiontodetail.Itcan take anywhere fromafew minutestoa fewhoursto
create a part,dependingonhowcomplex the item is.
Current Applications
Sinteringdirectmetal isprimarilyusedtocreate repairparts,particularlythose usedinthe medical,dental,and
aerospace industries.However,itisalsobeingexperimentedwithasa solutionforbuildingthe partsneededto
manufacture actual aircraft.In fact,DMLS has alsobeenusedtocreate several complex partsforthe SuperDracorocket
engine,whichisusedinrocketsandspace transportvehicles.Manymanufacturersalsouse itfor“limitedrun”partsthat
mightotherwise be extremelyexpensivetoproduce.
DMLS Benefits

2. Thisprocessmakesefficientuse of rawmaterialssothat waste isgreatlyreduced.Inmanycases,partsmay alsobe
producedondemand,therebyeliminatinglongwaittimesthatcouldslow the manufacturingprocess.Beingable to
produce parts ondemandalsomeansthere isno needtostock a great deal of inventory.DirectMetal LaserSinteringis
alsoable to produce parts thathave a greatdeal of strengthanddurability,soqualityisnotaffected.Inthe future,
widespreaduse of lasersinteringcouldtherefore reduce costssignificantly,while alsoimprovingqualityand
streamliningoperations.
Researchersare justbeginningtodiscoverthe multitudeof usesforsinteringdirectmetal.Itisquite possi ble that
factoriesof the future will utilize thistechnologyforthe majorityof theiroperations,asthe potential usesforSLS
sinteringare virtuallyunlimited.
About the Company: Based in Boston, Form 3D provides 3D printing services to manufacturers in the metal
and plastic additive industries. They employ a team of design experts who are adept at producing prototypes
from customer designs, allowing for custom products that are both innovative and cost effective. For more
information, please visit their website at http://form3ds.com.