Design guidelines for Direct Metal Laser Sintering (DMLS)

Copyright © Crucible Design Ltd. 2015

Design guidelines for Direct Metal Laser Sintering (DMLS) Introduction

Direct Metal Laser Sintering (DMLS) is an

additive manufacturing technology that is
based on melting layers of metal powder
using a powerful carbon dioxide laser.

The fact that layer-based production

processes do not require tooling has led to
the assumption that these technologies are
free of rules that govern design for
manufacture, like draft angles and
undercuts.

Whilst DMLS does not have to observe

conventional design rules, there are others
that do apply to the process, particularly if
reducing cost and waste is a consideration.

This presentation looks at these rules and

how they affect the design of parts built
using the DMLS process.
Design guidelines for Direct Metal Laser Sintering (DMLS) The benefits of DMLS

The primary benefits of DMLS are:

■ The ability to create internal as well as external complexity

■ The potential to build multiple parts in one process, maintaining joints, hinges, etc
■ The absence of any tooling, allowing complex shapes and geometry to be produced
■ The ability to vary wall sections to achieve optimum strength
Design guidelines for Direct Metal Laser Sintering (DMLS) The environmental impact of DMLS

The DMLS process requires a considerable amount of

energy, particularly if the costs of primary material
extraction and processing are taken into consideration.

However, considerable energy savings are possible if the

process is used to create parts that reduce CO2 emissions
as a result of their long term use.

Most of these applications involve reduced weight. Any part

that accelerates, for example, will save energy if its weight
is reduced. This is particularly true of any part that is used in
aerospace applications, especially if the part is used many
times. Another area is improved thermal efficiency,
particularly of parts like heat sinks, etc.

The way DMLS parts are designed can also have a

significant effect on their energy use, particularly in terms of
the way the part is built within the process, the amount of
post-machining that is required and how much waste is
generated. These issues will all be examined in the
following sections.
Design guidelines for Direct Metal Laser Sintering (DMLS) The DMLS process

1. A layer of powder (approx 0.02mm to 0.08mm thick) is deposited 2. The roller then deposits another layer of powder 3. The laser then fuses the
on the build platform by a recoating blade. The bottom layer of the as the build platform lowers one layer and the second layer to the first.. and so
part is then created by the laser, which locally melts the powder. powder reservoir is raised by the same amount. on...

4. As the layers build, the level in the build ...revealing the part attached to the
5. When the final layer of the part has
chamber goes down and the powder reservoir build platform.
been built, the powder is removed.....
base rises.
Design guidelines for Direct Metal Laser Sintering (DMLS) The materials
Design guidelines for Direct Metal Laser Sintering (DMLS) The build platform

multiple parts stacked

Build platform is made of steel plate. One Parts are built vertically up from the base. Multiple Build platforms are typically 250mm x
standard size for the base is 250mm x layers of parts are only possible if they can be 250mm at the base and either 215mm or
250mm. stacked on top of each other and cut apart after the 315mm high.
build.

cutting path

Before the parts are removed from the base, the whole platform is placed in a Material left on the base (usually only a ....and the machined base is now
furnace for several hours to relieve mechanical stresses. The parts are then few millimetres) is removed by ready for another build.
removed from the base by EDM (Electrical Discharge Machining) - also known machining....
as 'wire cutting'. The path can help define the geometry of the finished part.
Design guidelines for Direct Metal Laser Sintering (DMLS) Design basics – building layers

The most straightforward geometry to build in DMLS is a vertical 'extruded' form from
the build platform, where each layer builds on the geometry directly below it.
Design guidelines for Direct Metal Laser Sintering (DMLS)
The powder in the build chamber
does not provide any support to
the part as it builds, so any angled
surfaces will ideally be self-
supporting.
Small holes can be accommodated
easily. Holes of less than 6mm
diameter are ideal.
supporting structure
If the angle is too acute, the surface will
need a supporting structure built in as part
of the model. This supporting structure will
then need to be removed by machining or
wire cutting, increasing energy use.
rough surface
Larger circular holes will result
in a roughened surface at the
top which may need post-
machining.
The minimum angles that will be self
supporting are approximately:
- Stainless steels: 30 degrees
- Inconels: 45 degrees
- Titanium: 20-30 degrees
- Aluminium: 45 degrees
- Cobalt Chrome: 30 degrees
Large holes will require support structures to
be added in the centre to prevent the part
collapsing or becoming distorted during the
build process. These supports will need to
be removed by wire cutting or machining.
Design basics – angled surfaces
rough surface
If the angle is near the point where it
needs supports, the downward facing
surface will become rough and may
require considerable post-finishing.
If the hole has an angled or arched
upper area it will probably not require
any supports. This is one of the features
of DMLS that can have a significant
impact on the design process.
Design guidelines for Direct Metal Laser Sintering (DMLS)
Any downward facing surface will require support.
Support structures will need to be removed by
wire cutting or machining, which will increase the
energy and waste involved in the process.
An alternative to this approach will be to turn the part through 45 degrees to
make all the surfaces angled and remove the need for supports. Orientation is
a major issue in finding the most efficient build method - please see item 3 in
Other Issues for more details on the limits and possible pitfalls of using angled
edges like the ones shown above...
The most simple support structure will fill the hole
that creates the downward facing surface. This
can be removed by wire cutting or machining.
supports
If the top surface of the hole can be
made of a series of angles (which are
self supporting) the supports can be
minimised to the base of each angled
surface.
Design basics – downward facing surfaces
An offset support structure can be used that will be easier to remove.
In this case, the base of the support will be cut when the part is
removed from the base by wire cutting, leaving one edge to be cut in
order to remove the rest of the support.
If the hole is simply for weight reduction or cooling, for
example, it can be modified as a series of semi-
circular topped slots which will not require supports.
However, the 'pillars' between the holes need to be
self-supporting.
Design guidelines for Direct Metal Laser Sintering (DMLS)
As the re-coater blade passes over the part, depositing
another layer of powder, it can touch the layer below,
sometimes with force. The orientation of the part is,
therefore, important. The ideal geometry is a circular
profile which provides a smooth lead in for the blade, and
a stable cross section as it builds.
Any flat surfaces need to be at least 5 degrees
from parallel with the blade to allow the blade
to touch the part at a point, not a face.
An open 'U' or similar shape is also ideal,
as the lead in for the blade is again
rounded, and the basic profile will be strong
as it builds, resisting the force of the
recoating blade.
In addition to touching the part at an angle, it
helps if the geometry is inherently stiff, which will
resist bending forces as the re-coater blade
passes over the part.
Design basics – direction of build and cross sections
The 'worst case' geometry would be a thin
section parallel to the re-coater blade. The blade
will tend to 'bounce' off the parallel wall, and the
section itself will not resist the force of the blade
as it builds.
Long, thinner parts with rounded ends will build well, as
they also provide a smooth lead in for the blade and are
inherently stiff. However, all these issues need to be
considered in parallel with the other limits (build angles,
etc) mentioned elsewhere in this section.
Design guidelines for Direct Metal Laser Sintering (DMLS) Design basics – part strength during the build process

The exact proportions will always depend on the specific

As the re-coater blade passes over the part, more To prevent these problems, vertical sections need
geometry, but if the section gets too high, there is a danger
force will be applied to the geometry as it gets taller. to be bridged at certain points. The best method
that the re-coater blade will bend the part, and possibly
As a rule of thumb, the ratio between the section and of achieving this will be to use 'arches' to avoid
damage itself in the process, terminating the build sequence.
the height should be no more than 8:1. the creation of downward facing flat surfaces.

part will be very

weak at this point in
the build process

Even a part that will be strong when it is This kind of structure may need a If the reason for the open structure is simply
finished may need some support during the simple support structure up the weight reduction, it may be easier to perforate it
build process. This triangular section will be middle to provide some rigidity with holes (ideally less than 6mm in dia) that will
very weak as the build gets close to the apex. before the part is completed. reduce weight, but not require any supports.
Design guidelines for Direct Metal Laser Sintering (DMLS) Design basics – other issues

1. Avoid sharp edges. Very sharp edges cannot 2. Avoid thick sections. The heat build up when creating very 3. Avoid angles facing into the re-coater blade.
be built in DMLS, and it is better to design parts large horizontal sections can affect the build geometry, Angled parts that lean into the path of the re-
with minimum radii of approximately 0.5mm. particularly when using titanium. A better approach is to angle coater blade may cause the blade to collide
the part to minimise the horizontal section at any one time. with the part and terminate the build.

5. Use the wire cut removal path. The path 6. Build multiple parts. The nature of the DMLS
4. Avoid sharp edges. Sharp corners can act as
used to wire cut the part from the base can be process allows for multiple parts to be built 'in
'stress raisers' in DMLS in the same way as they
used as an integral part of the component situ'. This can save considerable time and
can in most processes. Always try to use radii on
design, rather than simply as a straight cut. assembly cost for appropriate geometry.
corners instead of sharp edges.
Design guidelines for Direct Metal Laser Sintering (DMLS) Supports – what do they do?

Supports are a 'necessary evil' in the DMLS

process. Good design practice will minimise them,
as they use a lot of energy - both in their
construction and removal - but they also fulfil a
number of vital functions within the process:
Large amount of support structure that
needs to be built (and then removed) to
support downward facing surfaces during
the build process

1. They support the newly melted surface,

particularly on downward facing surfaces and
shallow angles.
2. They can prevent the new geometry from
deforming.
3. They dissipate heat away from the newly formed
geometry, and
4. They provide temporary support for geometry
that will be strong when complete, but that is
weak during the build process. (see 'part
strength during the build process').
Geometry changed to simple curve
that can be built without supports
The ideal situation is to design a part that requires
no supports at all (see images on the right for
theoretical worst and best case scenarios).The
reality is that it is rarely possible to design parts that
require no supports at all, but minimising them will
save time, energy, and money.
Design guidelines for Direct Metal Laser Sintering (DMLS) Supports – types of support

supports
hole for removed
wire cutting

2. Offset supports. Offset supports require less

1. Simple fill in. The most simple form of support is to fill in the area that needs All support structures are
machining. They rise vertically and then angle in to
support, and then cut this out when the build is complete by wire cutting or formed from fine lattices, to
support specific surfaces. The base of the support is
machining. If the support area is to be removed with wire cutting, a small hole minimise energy
usually removed with the wire cut removal of the part,
needs to be placed in the support area to allow the wire to be located. consumption and build time
requiring only the supported surface to be machined.

support
from base

‘buttress’
support
3. Overhanging surfaces. Horizontal overhanging
4. Supports for curved surfaces. Sometimes, it is necessary to
surfaces can be supported from the base, although
support a downward facing curved surface to prevent the
this will require a considerable amount of material and
geometry failing or a very rough surface being formed. In this
energy. A better solution is to 'buttress' the surface
case, a support structure is formed under the part which is then
from the main geometry at an angle. Better still,
removed by wire cutting or machining when the part is removed
design the support into the geometry and remove the
from the base.
need for any additional work.
Design guidelines for Direct Metal Laser Sintering (DMLS)
Heat treatment
The build platform needs to be heat
treated before the parts and
supports are removed. There are
two reasons for this:
■ Age hardening of the
parts, and
■ Stress relieving prior to
removing the parts.
There are three methods commonly
used:
■ Electrical furnace
(above)
■ Vacuum furnace, and
■ Hot Isostatic Pressing
(HIPing)
Removal of supports
Supports can be very light tubular
forms, like the ones shown above
supporting dental copings, or heavy
sections supporting large downward
facing surfaces. They are usually
removed either by wire cutting - where
there is clear path for the wire - or
machined off, either by CNC
equipment or manually.
The best supports are those that can
be removed easily by the same wire
cutting process that is used for
removing the parts themselves.
Heat treatment, post machining and finishing
Post finishing operations
In addition to removing the supports, DMLS parts
usually require some post finishing. This can
include any of the following:
■ CNC machining (to achieve the required
tolerances)
■ Blasting (to improve surface finish and relieve
stresses):
■ Shot peening: Steel & ZrO2 media
■ Ti: Wet blasting with Al2O3 media
■ Polishing (to achieve a good cosmetic finish):
■ Manual
■ Automatic (Microtek-MMP Process)
To find out more about this process,
visit www.firstsurface.co.uk.
Design guidelines for Direct Metal Laser Sintering (DMLS) Other considerations - the impact of part stresses

The very high temperatures

involved in the DMLS process can
cause significant stresses to build
up in parts as they build. These
stresses can result in:

■ Delamination of the
layers
■ Cracks in the part
■ Distortion and
■ Warpage during post
finishing

These problems can be minimised

or avoided by shot peening the
parts to relieve stresses and/or
heat treating prior to removing the
parts from the build platform.
Strong support structures can also
minimise the build up of stresses in
the part.
Design guidelines for Direct Metal Laser Sintering (DMLS) Other considerations - forming threads in DMLS parts

Threads can be formed

directly into parts,
depending on the size of
the thread and the
orientation. Threaded
areas should always be
vertical, and ideally have
sufficient clearance
around the thread to allow
a tap or die to be used to
ensure that it is clean.

Smaller threaded areas

should be left off the CAD
file, and post-machined
(Drilled and tapped or
thread milled).
Design guidelines for Direct Metal Laser Sintering (DMLS) Other considerations – wall thicknesses

Wall thicknesses are somewhat

material dependent, but as a rule
of thumb, wall sections should
not fall below 1mm.Very thin wall
sections - or placing a thin
section against a thick section -
may result in significant distortion
due to the very high temperatures
involved in the process.

Fine detail is possible, however,

particularly in the vertical plane.
The illustration on the right shows
a section of a pipe with a wall
section of 0.9mm with a hole
running through it of 0.4mm
diameter.
Design guidelines for Direct Metal Laser Sintering (DMLS) Case study – bicycle pedal

If the geometry is modified to reduce the number of downward

A conventional 'rat trap' bicycle pedal (left) has a large number of surfaces. If it is built in the
facing surfaces (mainly by putting in a number of 45 degree
horizontal plane, the large number of downward facing surfaces will require a significant
angled surfaces) the amount of supports needed is reduced
amount of support (right). A large number of these can be offset, which will reduce the
significantly (right).
removal time, but building the part would require a considerable amount of energy.

However, by changing the orientation of the

part to vertical, the number of supports This vertical orientation, combined with design changes to the pedal, would
needed is dramatically reduced. allow designs to be produced that require no supports at all.
Design guidelines for Direct Metal Laser Sintering (DMLS) Conclusions and critical issues

■ The design rules for DMLS are based on

the efficiency of the build process.
■ The design needs to consider the
construction of the part layers throughout
the process, particularly those stages
when the part will be inherently weak.
■ Part orientation is critical – particularly in
relation to the re-coater blade and the
minimisation of supports.
■ Consider the wire erosion process that
removes the part from the build platform
as part of the design – it can form critical
geometry and reduce post-machining
time and cost.
■ Get creative. Design around these
limitations using the strengths of the
process – the ability to build layers on top
of each other that ignore conventional
manufacturing geometry.
Design guidelines for Direct Metal Laser Sintering (DMLS)