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3D printing services

Additive Engineering Solutions

There are many industrial powder bed fusion technologies available for metal 3D printing, of which additive process Direct Metal Laser Melting (DMLM) or Direct Metal Laser Sintering (DMLS) have been around for as long as metal printing has existed.

What is Direct Metal Laser Melting ?

DMLM is an additive manufacturing process that uses lasers to melt ultra-thin layers of metal powder to build complex 3D objects. A CAD model generates a STL file which is then sliced with software to be uploaded to a machine to build the part one cross section layer at a time. The use of a laser fully melts selective sections in the layer of metal powder to form complex end use parts that are fine, dense and homogenous. Parts build using DMLM have excellent mechanical properties and are comparable to wrought materials, high detail resolution and exceptional surface quality. The final metal parts require little, if any, finishing.

What is the difference between DMLM and DMLS?

While DMLS is often used to refer to both processes, DMLS uses lasers to heat particles below melting point so they adhere to one another. DMLM while similar, has the material completely melted to create ultra -thin liquid pools, which solidify as they cool. DMLM is becoming the preferred method where complete melting occurs.

Case Study

Space

Traditional antenna manufacturing consists of complex large and heavy systems which could lead to higher launch costs and inconsistent radio frequency (RF) performance at higher frequency bands. Utilising DMLM, Optisys consolidated 100 parts into one part, reducing leadtime from 11 to 2 months and reducing component weight by consolidating 100 parts into 1 part, reducing lead time from 11 months to 2 months, reducing weight by 95% and size by 80%.

Have a similar requirement for your project?

3D printed Space component

Why use Additive Engineering for metal additive manufacturing?

Advanced manufacturing requires the use of innovative technology to improve products or processes.

The mechanical engineering team at Additive Engineering are experienced in rapid prototyping, conventional manufacturing for mass production such as CNC machining and a range of additive manufacturing technology solutions for aerospace and medical bespoke products. 

Whether your requirements involve transitioning from traditional manufacturing processes or creating a complex lattice structure, the Additive Engineering team has the expertise in both traditional manufacturing methods and additive manufacturing processes to advise on the optimal manufacturing method.

Lattice structure

Clean-room environment to meet industry standards

To meet the stringent requirements of both medical and aerospace customers, the facility set up is modelled to manufacture parts in a clean-room environment with the objective to meet the highest standards of both medical and aerospace industries.

Proven technology

Additive Engineering utilises the proven 3D printer of GE Concept Laser Mlab 200R, to 3D print products with high surface quality and outputs the finest part structures. The Additive Engineering team has the experience to assist you in improving design for additive manufacturing in complex components that are too difficult and costly to manufacture using subtractive manufacturing methods.

Simplified delivery for ready to use products

Drawing on our extensive knowledge in materials from GE to our industry experience in the medical industry, we combine design, simulation, additive manufacturing, heat treatment, testing, sterilisation and packaging to ensure the complete part is delivered, ready to be used.

Qualified materials

Materials we can additively manufacture include:

  • Titanium Ti6Al4V ELI Grade 23
  • Stainless Steel 17-4 PH
  • Cobalt Chromium alloy
  • Hastelloy

If there is a metal alloy or raw material that is not listed, contact us to discuss your metal AM requirements.

Capabilities

Design for manufacturability assistance
Additive manufacturing conducted in a clean-room environment
Manufacturing standards modelled after medical ISO13485 and aerospace AS9100 standards
Powder to product traceability
DMLM Additive Manufacturing in bio-compatible titanium Ti6Al4V, stainless steel 17-4PH, CoCr alloy, Hastelloy, and SLS in medical grade PA2200
Tamper-proof packaging
Heat Treatment
Polishing and full finishing
Sterilisation
Our certified powders undergo stringent quality control to meet performance requirements. We also offer mechanical data to enable material selection and an optimised design to manufacture process.

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