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ScienceDirect
IFAC-PapersOnLine 49-29 (2016) 103–110
3D
3D Metal
Metal Printing
Printing Technology
Technology
3D
3D Metal Printing Technology
3D Metal Printing
Metal Printing Technology
Technology
Thomas
Thomas Duda*.
Duda*. L.
L. Venkat
Venkat Raghavan**
Raghavan**
Thomas
Thomas Duda*.
Duda*. L.
 Venkat
L. Venkat Raghavan**
Raghavan**
Thomas Duda*. L.  Venkat Raghavan**
*Pentair Valves & 
Controls, Schaffhausen, Switzerland;
*Pentair Valves & 
Controls, Schaffhausen, Switzerland;
*Pentair
*Pentair Valves
Valves &
e-mail:
& Controls, Schaffhausen,
Thomas.Duda@pentair.com
Controls, Schaffhausen, Switzerland;
Switzerland;
e-mail:
*Pentair Valves &
e-mail: Thomas.Duda@pentair.com
Controls, Schaffhausen,
Thomas.Duda@pentair.com Switzerland;
**Pentair Global
e-mail:
**Pentair e-mail: Engineering Center, Bangalore,
Bangalore, India
Thomas.Duda@pentair.com
Global Engineering
Engineering Center, Bangalore, India
**Pentair Global Thomas.Duda@pentair.com
Center, India
e-mail:
**Pentair GlobalVenkat.Raghavan@pentair.com
Engineering
e-mail:
**Pentair Global
e-mail: Engineering Center,
Center, Bangalore,
Bangalore, India
Venkat.Raghavan@pentair.com
Venkat.Raghavan@pentair.com India
e-mail:
e-mail: Venkat.Raghavan@pentair.com
Venkat.Raghavan@pentair.com

Abstract: 3D3D Printing

Printing or or Additive manufacturing
manufacturing isis a novel method
method ofof manufacturing
manufacturing parts
parts directly
directly from
from
Abstract:
Abstract:
digital
Abstract: 3Dby
model
3D Printing
using
Printing or Additive
or Additive
layer by
Additivelayermanufacturing
material is aaa novel
build-up
manufacturing is novel method
approach.
novel method oftool-less
This
of manufacturing parts directly
manufacturing
manufacturing parts directly
method from
can
from
digital model
Abstract:
digital 3Dby
model by using
Printing
using layer
layer by
or Additive
by layer
layer material
material build-up
manufacturing
build-up approach.
is a novel method
approach. This
oftool-less
This manufacturing
manufacturing
tool-less method
parts directly
manufacturing method can
from
can
produce
digital
produce fully
model
fully dense
by using
dense metallic
layer
metallic parts
by in
layer
parts in short time,
material
short with
build-up high precision.
approach. This Features
tool-less of additive
manufacturing manufacturing
method can
digital
produce model
like freedom
freedom
produce fully
by
fully of using
dense layer by
metallic
part metallic
dense design, part
layer
parts
part
parts short time,
inmaterial
complexity,
in short
with
build-up
time, with
light
time,
high
weighting,
with high
precision.
approach.
high Features
This tool-less
precision.
part consolidation
consolidation
precision. Features
of additive
Features manufacturing
of and
of additive
design
additive
manufacturing
method can
manufacturing
for function
function
manufacturing
like
produce
like fully
freedom of of
of part
dense design,
metallic
part design,
design, partscomplexity,
in short
part complexity,
complexity, light
time, weighting,
with high
light weighting,
weighting, part
precision.
part for Features
consolidation of and design
additive
and design for
manufacturing
for function
are
like
are garnering
freedom
garnering particular
part
particular interests
part
interests in
in metal additive
light manufacturing
part aerospace,
consolidation oil
and & gas,
design marine
for and
function
like
are freedom of
garnering
automobile
are garnering
part design,
particular
applications.
particular interests
Powder
interests in metal
part complexity,
bed
in metal additive
additive
fusion,
metal in which
additive
manufacturing
light weighting,
each
part for
manufacturing
powder
manufacturing bed
for
aerospace,
consolidation
for aerospace,
layer is
aerospace,
oil
and &
& gas,
oil design
selectively
oil & gas, marine
for
fused
gas, by
marine
and
function
marine and
using
and
automobile
are garnering
automobile applications.
applications. Powder
particular interests
Powder bed fusion,
in metal
bed in
in which
additive
fusion, which each powder
powder bed
manufacturing layer is
is selectively
for aerospace,
eachmanufacturing
bed layer fused
oil & gas,
selectively by
marine
fused by using
and
using
energy source
source
automobile like laser,
laser, Powder
applications. is the
the most
most
bed promising additive technology that can
can be by
used for
energy
automobile
energy source like
applications.
like laser, is
Powder
is the bed fusion,
most fusion, in
in which
promising
promising which each
additive
additive
powder
powder bed
bed layer
eachmanufacturing
manufacturing layer is
is selectively
technology that
selectively
technology that
fused
be
fused
can be used
by
used
using
for
using
for
manufacturing
energy source
manufacturing small,
like
small, low isvolume,
laser,
low volume,
the complex
most metallic
promising
complex parts.manufacturing
additive
metallic parts. This review
This review presents
presents overview
technology that
overview of 3D
can
of 3D
be Printing
used for
Printing
energy source like
manufacturing laser,
small, isvolume,
the most
lowapplications, promising
complex additive
metallic parts.manufacturing
This review technology
presents that can
overview be used
of applications
3D for
Printing
technologies, materials,
manufacturing materials,
small, advantages, disadvantages, challenges, economics and
technologies,
manufacturing
technologies, small, low
materials,
volume,
volume, complex
lowapplications,
applications, complex metallic
advantages,
metallic
advantages,
parts.
parts. This
This review
disadvantages,
disadvantages, review presents
challenges,
challenges,
overview
economics
presents overviewand
economics
of 3D
3D Printing
of applications
and Printing
applications
of 3D metal
of metal printing
technologies, technology.
materials, applications,
applications, advantages,
advantages, disadvantages,
disadvantages, challenges,
challenges, economics
economics and and applications
of 3D
of metal printing
technologies,
3D metal
3D printing
printing
technology.
materials,
technology.
technology.
applications
© 2016, IFAC (International Federation of Automatic Control) Hosting by Elsevier Ltd. All rights reserved.
of 3D metal printing technology.
Keywords: Additive
Keywords: Additive Manufacturing,
Additive Manufacturing,
Manufacturing, 3D 3D metal
3D metal print,
metal print, powder
print, powder
powder bedbed fusion,
bed fusion, economics,
fusion, economics, complexity
economics, complexity for
complexity for free
for free
free
Keywords:
Keywords: Additive Manufacturing, 3D metal print, powder bed fusion, economics, complexity for free
Keywords: Additive Manufacturing, 3D metal print, powder bed fusion, economics, complexity for free



1. INTRODUCTION 
1.
1. INTRODUCTION
INTRODUCTION 1.1
1.1 Powder
Powder BasedBased Fusion
Fusion (PBF)
(PBF)
1.
1. INTRODUCTION
INTRODUCTION 1.1
1.1 Powder
Powder Based
Based Fusion
Fusion (PBF)
(PBF)
Additive
Additive manufacturing
manufacturing (AM),
(AM), also
also known
known as
as 3D
3D printing,
printing, is
1.1
is aa
Powder Based Fusion (PBF)
Additive
process
Additive manufacturing
of joining
manufacturing (AM),
materials
(AM), to also
make
also known
objects
known as
as 3D
from
3D printing,
3D Inis
In PBF
model
printing, is a
PBF based
based technologies,
technologies, thermal
thermal energy
energy selectively
selectively fusesfuses
process
Additive
process of
of joining
manufacturing
joining materials
(AM),
materials to
to make
also
make objects
known
objects from
as 3D
from 3D
printing,
3D is aa
model
In
modelPBF
regions
In PBF based
of
based technologies,
powder bed.
technologies, thermal
Selective
thermal energy
laser
energy selectively
sintering/melting
selectively fuses
fuses
data,
processusually
of layer upon layer, as opposed to subtractive
regions of powder bed. Selective laser sintering/melting
data,
process
data, of joining
usually
usually layer
joining
layer
materials
upon
materials
upon
to
to make
layer,
layer, as
make
as
objects
objects from
opposed
opposed to
from
to
3D
3D model
In
subtractivePBF
regions
model
subtractive
(SLS/SLM),
based
of technologies,
powder
Direct bed. thermal
Selective energy
laser selectively
sintering/meltingfuses
manufacturing
data, usually
manufacturing
data, usually
methodologies.
layer upon
methodologies.
layer upon layer,
layer,
This
as
This
as
tool less
opposed
tool less
opposed to
to
regions
manufacturing
(SLS/SLM),
subtractive
regions
manufacturing
(SLS/SLM),
subtractive
of Direct Metal
of powder
powder
Direct
bed.
Metal
Metal
Laser
Laser Sintering
bed. Selective
Selective
Laser
laser
Sintering
Sintering
(DMLS)
(DMLS) laser
laser sintering/melting
sintering/melting
(DMLS) laser
laser
manufacturing
approach
manufacturingcan methodologies.
give industry
methodologies. This
new
This tool
design
tool less manufacturing
flexibility, cusing
(SLS/SLM),
reduce
cusing and
and electron
Direct
electron Metal beam
beam Lasermelting
melting (EBM)
Sintering
(EBM) (DMLS)are
are main
laser
main
approach
manufacturing
approach can
can give industry
methodologies.
give industry new
new tool less
Thisdesign
design less manufacturing
flexibility, (SLS/SLM),
reduce
cusing
manufacturing
flexibility, reduce and
representative
Direct
electron
processes
Metal beam
of
Laser Sintering
melting (EBM) (DMLS) laser
are(Bhavar
main
energy
approach
energy
approach use
use and
can
and
can shorten
give
shorten
give time
industry
time
industry to
new
to
newmarket.
design
market.
design Main
Main applications
flexibility, cusing
reduce
applications
flexibility, of
cusing
reduceof
and
and electron
representative
representative processes beam
electron
processes of PBF
beam
of PBF
based
based technologies
PBFmelting
melting
based
(EBM)
(EBM) are
technologies
technologies
main
(Bhavar
are(Bhavar
main
energy
additive
energy use
use and shorten
manufacturing
and shorten time to
include
time to market.
rapid
market. Main applications
prototyping,
Main applications of
2014).
representative
rapid
2014).
of Under
Under PBF
processes
PBF process,
of PBF
process, DMLS
based
DMLS is
technologies
is an
an additive
(Bhavar
additive
additiveusemanufacturing
energy manufacturing
and shorten time include rapid Main
to market. prototyping,
applicationsrepresentative
rapid
2014).
of Underprocesses
PBF of PBF
process, based
DMLS technologies
is an (Bhavar
additive
additive include rapid prototyping, rapid
manufacturing
2014). Under (AM) PBFor
or rapid
process,prototyping
DMLS (RP)
is process that
tooling,
additive
tooling,
additive
direct
direct part
manufacturing
part
manufacturing
production
include
production
include
and
and part
rapid
part
rapid
repairing
prototyping,
repairing
prototyping,
of
of plastic,
manufacturing
rapid
2014).
plastic,
manufacturing
rapid Under (AM)
(AM) PBFor rapid
process,
rapid prototyping
DMLS (RP)
prototyping is an
(RP) an additive
process that
additive
process that
tooling,
metal, direct
ceramic part
andproduction
composite and part
materials.repairing
The of
two plastic,
uses
main
uses metal
manufacturing
metal powder
powder(AM) and
andor a
a high
rapid
high power laser
prototyping
power laser to sinter
(RP)
to sinter together
process
together thata
tooling,
metal,
tooling, direct
direct part
ceramic and
part production
composite
production and part
part repairing
andmaterials. The
repairing of
of plastic,
two manufacturing
main
uses
plastic, metal powder(AM) andora rapid
high prototyping
power laser (RP)
to sinterprocess
together thataa
metal, ceramic and composite materials. The two main
useable
uses part.
metal This
powder method
and is capable of producing very dense
parameters
metal,
parameters
metal,
of
ceramic
of
ceramic
any
anyand
and
metal
metal AM
composite
AM
composite
process
process are
materials.
are
materials.
type
The
type
The
of
of input
two
input
two
raw
useable
main
uses
raw
useable
main part.
metal
part.powder
This and aa high
This method
method high
is
power
is capable
capable
power of laser
of
laser to
to sinter
producing together
very
sintervery
producing denseaa
together
dense
parameters
material
parameters and of
of any
energy
any metal
source
metal AM
AM process
used to
process are
form
are type
the
type of
part
of input raw
parts
useable
(Bhavar
input parts
raw but
but in
part.
in order
This
order to
to achieve
method
achieve is gas
capable
gas or
or pressure
of producing
pressure tightness,
very
tightness, post-
dense
post-
material
parameters and of energy
any source
metal AM used to
process form
are the
type part
of input useable
(Bhavar
parts
raw butpart.
in This
order method
to achieve is capable
gas or of producing
pressure very
tightness, dense
post-
material
2014).
material and
Input
and energy
raw source
material
energy source canused
be
used to
used
to form
in
form the
the
the part
form
part of(Bhavar
treatment
parts
metal but
treatment
(Bhavar is
in
is often
order
often required.
to achieve
required. Most
gas
Most or tradenames
pressure
tradenames such
tightness,
such as
as laser
post-
laser
2014).
material Input
and raw material
energy source can be
used used
to in
form the
the form
part of parts
metal but
treatment
(Bhavar in
is order
often to achieve
required. gas
Most or pressure
tradenames tightness,
such as post-
laser
2014).
powder
2014). Input
or
Input raw
wire
raw material
whereas
material can be used
laser/electron
can in the
beam form
or arcof metal
sintering,
treatment
can be
sintering, cusing
is often
cusing etc.
etc. are
required.
are describing
Most
describing the
the same
tradenames
same process
such
process but
as
but not
laser
not
powder
2014).
powder or
Input
or wire
rawwhereas
wire whereas can bebe used
used in
material laser/electron
laser/electron in the
the form
beam
beam or arc
form
or arc
of metal
ofcantreatment
metal
can be
sintering,
be
different
sintering,
is often
cusing
technologies.
cusing
required.
etc.
etc. are
are The
Most
describing
process
describing
tradenames
the
is
the same
very
same
such
process
similar
process
as
but
to
but
laser
not
an
not
used
powder
used as
as energy
or
energywire source
source (Fig.
whereas
(Fig. 1).
laser/electron
1). beam or arc different
can be
sintering,
different technologies.
cusing etc.
technologies. are The process
describing
The process is
the
is very
same
very similar
process
similar to
but
to an
not
an
powder
used as or
energywire whereas
source (Fig.laser/electron
1). beam or arc can be
existing
different AM process
technologies. called
The Selective
process Laser
is verySintering
similar (SLS),
to an
used as energy source (Fig.
used as energy source (Fig. 1). 1). existing
different
existing AM
AM process
technologies.
process called
The
called Selective
process
Selective Laser
is very
Laser Sintering
similar
Sintering (SLS),
to
(SLS), an
both
both SLS
existing
SLSAM and DMLS
andprocess
DMLS calledare
are conceptually
Selective the
the same process, but
existing
both SLS AM and process
DMLS called
are Selective Laser
conceptually
conceptually Laser
the
Sintering
same process,
Sintering
same process,
(SLS),
(SLS),but
but
instead
both
insteadSLS of
of using
and
using polymers
DMLS
polymersare or coated
conceptually
or coated metal
metalthepowders
same
powders in the
process,
in the case
but
case
both SLS
instead of and
using DMLS
polymersare orconceptually
coated metalthepowders
same process,
in the but
case
of
of SLS,
instead
SLS,of DMLS
using uses
uses uncoated pre-alloyed metal
metal powders as
instead
of SLS, using polymers
DMLS
ofDMLS polymers
uses
or
or coated
uncoated
uncoated coated metal
metal powders
pre-alloyed
pre-alloyed powders
metal
in
in the
the case
powders
powders as
case
as
the
of
the sintering
SLS, DMLS
sintering material
uses
material (Gratton
uncoated
(Gratton 2015).
pre-alloyed
2015). The
metal
The electron
powders
electron beam
beam as
of
the SLS, DMLS
sintering uses
material uncoated
(Gratton pre-alloyed
2015). metal
The powders
electron beam as
melting
the (EBM)
sintering technology
material uses
uses aaa2015).
(Gratton heated
heated powder
The bed
bed ofof metal
melting
the
melting (EBM)
sintering
(EBM) technology
material
technology(Gratton
uses 2015).
heated The electron
powder
powder electron
bed of
beam
metal
beam
metal
in
in a
melting
a vacuum
(EBM)
vacuum that
that is
is then
technology
then melted
uses
melted a and
heated
and formed
powder
formed layer
bed
layer by
of
by layer
metal
layer
melting
in (EBM)
aa vacuum technology
that is then uses
melted a heated
and powder
formed bed
layer of
by metal
layer
using
in
using
in a an
vacuum
an
vacuum electron
that
electron
that beam
is then
beam
is then energy
melted
energy
melted source
and
source
and similar
formed
similar
formed to
layer
to
layer that
by
that
by of
layer
of
layeran
an
using
electron
using an
an electron
beam
electron beam
beam energy
welding/electron
energy source
microscope
source similar to
(Herderick
similar to that
that of
2011).
of an
an
electron
using
electron an beam
beam welding/electron
electron beam energy
welding/electron microscope
source
microscope (Herderick
similar to that
(Herderick 2011).2011).
of an
electron
electron beam
beam welding/electron
welding/electron microscope
microscope (Herderick
(Herderick 2011).2011).
Fig.
Fig. 1.
1. Common
Common metal
metal additive
additive manufacturing
manufacturing process.
process. 1.2 Direct Energy Deposition (DED)
Fig. 1. Common metal additive manufacturing process. 1.2
1.2 Direct
Direct Energy
Energy Deposition
Deposition (DED)
(DED)
Fig.
Fig. 1. Common
1. AM
Common metal additive
metalcan
additive manufacturing
manufacturing process.
process. 1.2 Direct Energy Deposition (DED)
Metal processes be broadly classified into two major 1.2
In Direct
DED Energy
based Depositionfocused
technologies (DED)thermal energy is used to
Metal
Metal AM
AM processes
processes can
can be
be broadly
broadly classified
classified into
into two
two major
major In DED based technologies focused thermal energy
energy is is used
used to to
groups,
Metal AM-- Powder Bed
processes canFusion
be based
broadly technologies
classified into (PBF)
two and
major In DED
fuse
In DED based
materials
based technologies
(powder
technologies or focused
wire form)
focused thermal
by
thermalmelting
energy as isthey
used are
to
groups,
Metal
groups, AM Powder
- Powder Bed
processes
BedcanFusion
be
Fusion based
broadly
based technologies
classified into
technologies (PBF)
two
(PBF) and
major
and fuse
In DED materials (powder
based technologies or wire form)
focused by
thermalmelting as
energyasistheythey
usedareare
to
Directed fuse materials (powder orEngineered
wire form) by melting
Directed-- Energy
groups,
groups,
Directed
Powder
Energy
Energy
Deposition
Bed
Bed Fusion
Deposition
PowderDeposition
(DED)
based
(DED)
Fusion
(DED)
based
based
basedbased
technologies.
technologies (PBF)
technologies.
technologies
technologies.
Both
and
Both
(PBF)Both being
and fuse
fuse
deposited.
beingmaterials
deposited.
materials
Laser
(powder
Laseror
(powder or wire form)
Engineered
wire form)
Net
by
Net
by
Shaping
melting
Shapingas
melting as
(LENS),
they
(LENS),
they are
are
of these
Directed technologies
Energy can be further classified based on the being deposited. Laser Engineered Net Shaping (LENS),
of these
Directed
of Energy Deposition
these technologies
technologies be(DED)
can be
Deposition
can furtherbased
(DED)
further
technologies.
classified
based
classified onBoth
based on
technologies.
based Both
the
Direct
the being
being
Metal
Metal Deposition
Direct deposited.
deposited. Laser
Deposition (DMD),
(DMD), Electron
Laser Engineered
Engineered Net
Electron Beam
Beam Free
Net Shaping
Shaping Free Form
(LENS),
Form
(LENS),
type
of of
these energy source
technologies used
can (Bhavar
be 2014).
further classified based on the Direct Metal
Fabrication
Direct Metal Deposition
(EBFFF)
Deposition and (DMD),
arc
(DMD), Electron
based AM
Electron Beam
are
Beam Free
some
Free ofForm
Formthe
type
of
type of
these
of energy
energy source
technologies
source used
used (Bhavar
can (Bhavar 2014).
be further classified based on the Direct
2014). Fabrication
Metal (EBFFF)
Deposition and arc
(DMD), based AM
Electron are
Beam some
Free ofFormthe
type Fabrication (EBFFF) and arc based AM are some of the
type of
of energy
energy source
source used
used (Bhavar
(Bhavar 2014).
2014). popular
Fabrication
popular
Fabrication
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2405-8963 © 2016, IFAC (International Federation of Automatic Control) Hosting by Elsevier Ltd. All rights reserved. (Bhavar 2014). DMD is
Copyright
Copyright © 2016 IFAC 103
Peer review©
Copyright 2016
©under IFAC
2016 responsibility
IFAC 103
of International Federation of Automatic
103Control.
Copyright © 2016 IFAC
10.1016/j.ifacol.2016.11.111 103
Copyright © 2016 IFAC 103
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based on a powder injection system that is coupled with a current readiness level of AM for different fields of
fiber laser on a robotic arm. DMD is well-suited for repair of application (Berger 2013).
existing tooling, adding features to large parts, or for the
manufacture of new parts (Herderick 2011). Electron Beam
Freeform Fabrication (EBFFF) uses a focused electron beam
in a vacuum environment to create a molten pool on a metallic
substrate [Electron beam 2016]. RPD Rapid plasma
deposition makes use of an argon plasma, in which a metal
wire is melted and the argon gas is propelling the molten
droplets towards the substrate or base plate, where the part is
created layer by layer (Paul 2015, Norsk 2016). Directed
energy deposition for metal AM is less widespread for the
Fig. 4. Examples of 3D Printed Products.
additive manufacturing of a whole part (whereas exception
exists, RPD), primarily due to lower accuracy and required
post-processing. In contrary, DED has a long-standing history
in repair application. The most widespread technologies in
this area are the Cold Gas Spraying (as shown in figure 2
below), High Velocity Oxygen Fuel spraying and Laser metal
deposition. The next figure 3 gives a comparison between AM
Processes - PBF and DED (Berger 2013).

Fig. 4a. Norsk Titanium RPD Aero part (Paul 2015, Norsk
2016)

Fig. 2. Repair by Cold gas spraying. (a) Prior to spraying, (b)

as sprayed, (c) finished.

Fig. 4b. Hydraulic valve block (height 5 cm),

VTT Finland, 66% smaller than original design (VTT2015).

Fig. 3. Comparison of PBF vs. DED

1.3 Application of 3D Printing Technology

The 3d printing technology covering wide range of alloys

used in a variety of industries (including aerospace,
automotive, dental, jewelry, oil and gas, orthopedics printed
electronics, and tooling). Some of the potential applications
such as Oil and Gas Control Valve (Part of a control valve,
manufactured at the Kariwa plant, Niigata Prefecture, Japan,
hardware: Lumex avance 25) and Engine/Leap 1, Leap 56
Fuel Nozzle/Housing, LEAP FETT parts developed by GE,
Servo Controlled valves, impellers/pumps applications and
Stainless steel brackets components as shown in figure 4
(Webpages 2016, GE Newsroom 2015, Morris 2014)]. It
needs to be pointed out, that only very little information about
serial production and usage of complex parts exists. Many
examples, especially in the valve area, showing prototypes or
selected parts of a valve. The next figure 5 summarizes the
Fig. 5. AM Readiness Level.
1.3 Advantages and Disadvantages of the AM Process
Advantages are freedom of design, complexity for free,
potential elimination of tooling, lightweight design, part
consolidation by reducing assembly requirements, and
elimination of production steps. One example of the
advantages of AM is represented in the 2013 GE aircraft
engine bracket design challenge as shown in below figure 6.
By making use of the complexity for free, it was possible to
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come up with a new design which was 70% lighter than the
existing one (Alec 2015).
Fig. 6. 3D printed GE aircraft engine bracket.
The current disadvantages (AM still being a new technology)
are slow build rates, limited component size (restricted by the
size of the build chamber), considerable effort required for
application design and for setting process parameters,
dimensional accuracy, required post-treatment methods like
surface finishing and the stability and quality of the used
powder. Figure 7 is summarizing the current advantages and
disadvantages (Berger 2013).
Fig. 7. AM Advantages and Disadvantages.
Figure 8 is giving an overview about the manufacturing
readiness level of AM for different application (Berger 2013).
Fig. 8. AM Origin and Manufacturing Readiness Level.
105
1.4 Economics of 3D Printing Technology
The components considered for driving the additive
manufacturing cost are material cost, labor cost, machine cost,
and energy consumption. Material cost constitutes major
proportion of additive manufacturing cost for laser sintering
process. Labor cost would be 2- 3% and energy consumption
is less than 1%. (Thomas 2014). Metal AM started to gain
attention in aerospace, oil and gas, marine, automobile,
manufacturing tools and medical applications because of the
advantages offered by this process. First, it can reduce buy to
fly ratio considerably which is the ratio of input material
weight to final part weight. For conventional manufacturing
processes, buy to fly ratio for aerospace engine and structural
components can be as high as 10:1 and 20:1 respectively. AM
can produce near net shape using layer by layer addition of
materials as per requirement which can reduce buy to fly ratio
up to 1:1. Conventionally manufactured part may require a
number of different manufacturing processes like casting,
rolling, forging, machining, drilling, and welding etc. whereas
the same part can be produced by using AM which eliminates
required tooling and produces part in single processing step.
Several post treatment processes, at least the cutting off the
product from the base plate by wire edm is required and most
of part need also the removal of the support structures. Every
part manufactured by AM can be unique and produced in very
short time which enables mass customization. AM also
reduces assembly requirements by integrating number of parts
required in assembly into a single part. It reduces overall
weight, decreases manufacturing time, reduces number of
manufacturing processes required, reduces cost and material
requirements and optimizes required mechanical properties
(Bhavar 2014). The use of AM techniques are shown to be
advantageous for parts which have a high buy:fly ratio, have a
complex shape, have a high cost of raw material used for
machining from solid, have slow machining rates and are
difficult and expensive to machine. The specific cost of
material deposited by additive manufacturing systems
required to give a 30% saving over conventional Machine
from solid techniques is estimated for a typical aerospace-
Titanium alloy over a range of buy:fly ratios as shown in
below figure 9 (Allen 2015). In view of above information
and below graph shown in figure 10, using AM, geometrically
complex shapes with increased functional performance can be
manufactured at virtually no additional cost (Berger 2013).
Fig. 9. Specific Cost of AM material for a range of Buy:Fly
ratios.
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Fig. 12. AM technologies/materials selection.

Type Technology Materials

Powder bed and inkjet 3D printing (3DP)
Electron beam melting (EBM)
Selective laser melting (SLM)
Powder Bed
Fig. 10. Cost vs. Complexity between AM and conventional Selective heat sintering (SHS)
Selective laser sintering (SLS)
manufacturing methods. Direct metal laser sintering (DMLS)
Almost an metal alloy, powdered polymers
Almos an metal alloy including titanium alloys
Titanium alloys, superalloys, stainless steel, aluminium
Thermoplastic powder
Thermoplastic powder, metal powder, ceramic powder
Almost and metal alloy

But it needs to be noted, that in most cases, a simple copying
of the existing design made by conventional methods to AM
will lead not to a significant cost reduction. AM will be
beneficial, when the product performance is also enhanced as
shown in figure 11 (Berger 2013).
Fig. 13. Powder Bed Fusion Technologies and Materials.
3. DIRECT METAL LASER SINTERING - DMLS
3.1 Principle

Direct Metal Laser Sintering (DMLS) is a laser-based rapid

Fig. 11. AM – Cost and Gains.
2. TECHNOLOGY SELECTION FOR METAL ADDITIVE
MANUFACTURING
Several technologies have been developed for additive
manufacturing– Powder bed fusion is the leading technology
and also most relevant for metal objects as observed in below
figure 12. Direct Metal Laser Sintering – DMLS, is the most
preferred powder bed fusion technology in view of short
manufacturing time, cost effective assembly and wide variety
of metal parts as seen in figure 13 (Berger 2013). Complex
geometries and assemblies with multiple components can be
simplified to fewer parts with a more cost effective assembly.
DMLS does not require special tooling like castings, so it is
convenient for short production runs (Met 2016). It needs to
be noted, that SLS, SLM and DMLS is often used in
conjunction to describe the same basic technology.
prototyping and tooling process by means of which net shape
parts are fabricated in a single process. Complex parts can be
produced directly from 3D-CAD models by layer-wise
solidification of metal powder layers in portions of the layer
corresponding to the cross-section of the three dimensional
part in the respective layer (Syvaenen 2008). Figure 14 below
shows the basic components used in the DMLS process. The
basic principle of the DMLS Technology is to melt down thin
layers (20 - 60 μm) of Metal Powder with an electronically
driven Laser beam (200W) (Met 2016). The important parts of
DMLS machine are: the building platform, dispenser unit,
recoater unit, the laser system, precision optics such as F-
theta lens or varioscan, a high speed scanner and a computer
with process software (EOS2016, Surel 2008). Metal powder
is stored in dispenser unit and the recoater is used for coating
of metal powder of uniform layer thickness on steel base
plates. It needs to be noted, that SLM, SLS and DMLS is
describing basically the same process, main difference being
the nature of the powder.

Fig. 14. DMLS set-up.

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3.2 DMLS additive manufacturing process

A steel base plate is mounted on building platform. Prototype

part/mould is built on building platform. A layer of metal
powder of grain size smaller and smallest fraction below 6μm
is spread on a steel base plate. The laser beam sinters the first
layer. The building platform moves down by 20 μm. If
powder layer thickness is 20 micron, powder needs to be
much smaller in size. The build rate depends upon accuracy
and roughness. The recoater moves towards the dispenser.
The dispenser moves up so that sufficient powder is taken by
the recoater to spread a new layer of powder on the already
sintered layer. The laser sinters the second layer and thus the Fig. 15. Effect of large thermal stresses.
process continues till part gets completed (Gratton 2015).
Different parts can be built in one setup on a single base plate. 3.3 Main process problems
Layer by layer, it is possible to build any kind of shape and
geometry, even those which are impossible to obtain with any AM still being a young technology, exhibits a number of
other kind of technology. The accuracy is ± 0,05mm. The process problems, which needs to be known when developing
resulting DMLS 3D printed parts have different material a part to be produced by AM, especially SLM/DMLS
structure /mechanical properties of those obtained through
conventional techniques depending upon the materials. The - Different thermal boundaries expected during build
steps involved in building a prototype part/ mould on AM up (heating up or cooling down during build of the
machine is as follows: single layers).
- Creation of 3D CAD model of prototype part/mould. - Technology transfer between different systems
- Converting the CAD model to .STL format. (hardware supplier) not/very limited possible (R&D
- Support structure definition and smoothing of equipment should be the same as production
corners/edges is required equipment).
- Slicing the .STL model in to thin layers - Depending on optics, test results cannot be
- The layer file .SLI is fed to DMLS – AM / Rapid transferred (F-theta lens vs. varioscan).
Prototyping machine. - Argon cross flow stability.
- Stability of brush/recoater.
3.3 DMLS technology and design boundaries - (Random) laser path and directional material pattern,
- Breakdown of melt pool, Re-fusing for densifying
When applying AM, several boundary conditions compared to layer.
traditional design and processes are changing. Below listed Accuracy of overlapping laser paths (in case of
are the main differences, which need to be accounted for multiple lasers).
when planning to use AM technologies. - Powder handling (EHS issue)and delivery to system
- Best fit model vs. 6point hard nest reference system, - Purity of powder (supply chain- higher requirements
- Roughness (Rz) factor of deposition layer thickness compared to thermal spray application).
- Support structures during build required, which need - Re-use of powder (sieving, sizing, etc.).
to be removed later. - Parts cleaning.
- Wire EDM required to cut part from base plate. - Overhang surfaces & support structures, see figure
- Roughness is internal and external, which could 16 below (Alvarez 2014).
influence the flow behavior of internal channels, in
addition, the reduction of internal roughness requires
(sometimes) very complicated methods (roughness is
more waviness, therefore it is not removing burrs).
- Parts are normally NOT dense enough for (high)
pressure application without HIP process afterwards.
- Material structure differs from casting/forging
(sometimes better LCF, tensile values) (Slotwinski
2013).
- Material has preferred direction due build method
(random laser & path control to mitigate to a certain
extent).
- Design of part to avoid large thermal stresses (Refer
figure 15 below) (Kruth 2015). Fig. 16. Need and challenges regarding support structures.
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3.4 Main determining factors for productivity and cost
The cost of additive manufacturing is quite high, mainly to the
very slow build rate. Typical factors influencing this
parameter are:
- laser scanning speed,
- laser power,
- number of laser and scanners,
- overlap area of multiple lasers,
- required roughness (layer thickness),
- base plate preheating capability.
In addition, the productivity of the complete system is
influenced by the powder handling and exchange in
combination with the required cleaning of the built part in
order to remove the remaining powder. Most of the companies
delivering AM equipment have addressed this problem and
can deliver quick exchange system in order to minimize
downtime of the production equipment.
The figure 17 below describes the future trend for the key
parameters (Berger 2013).
Fig. 17. Future trend for key parameters.
The powder is identified as one of the major cost (and
problem) contributor to the AM process. Especially for (high
temperature) metal powder, several challenges exist as
described in below figure 18 (Alvarez 2014).
engineers in AM processes, leading to the situation, that the
full potential of AM is only slowly released. One contributing
factor might be that the range of standards, covering AM is
still very limited as shown below in figure 19, (VGB 2015).
Fig. 19. List of available standards for AM.
4. POWDER BED FUSION EQUIPMENT
EOS is a German company founded in 1989 that
manufactures equipment for metal AM focused on their Direct
Metal Laser Sintering (DMLS) technology. Typical DMLS
machines developed by EOS are EOSINT M 280, EOS M290,
EOS M400 and developed by 3D Systems are ProX 100,
ProX 200. It produces components by means of Additive
Manufacturing – fully automatically, without tools and based
directly on three-dimensional CAD design data. Typical build
volume by EOS: 250mm x 250mm x 325mm (9.85 in x 9.85
in x 12.8 in), 400mm x 400mm x 400mm (15.8 x 15.8 x 15.8
in) and 3D Systems: 250 mm x 250 mm x 330mm (9.85 in x
9.85 in x 12.9 in. Machines are user-friendliness, low-dust,
ergonomic working conditions, and data can be processed
conveniently at the workplace. The technology is used both
for rapid prototyping, as it decreases development time for
new products, and production manufacturing as a cost saving
method to simplify assemblies and complex geometries (EOS
2016). The figure 20 gives an overview about the different
manufactures and a historical breakdown of sold equipment
(Berger 2013).

Fig. 18. Problems related to powder quality.

3.5 Human skills and availability of standards

DMLS is automated process but skilled labor is required.

Direct labor costs are low but skilled labour required at all
times (Vazquez 2016, Swift 2013). It needs to be noted, that
there is still a lack of education and training of design Fig. 20. Additive manufacturing hardware market overview
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4. CONCLUSION
There is a rich landscape of available technologies and
materials for metal additive manufacturing. The range of
currently available materials is already very large, ranging
from titanium alloys and nickel alloys to high-grade stainless
steels and is increasing rapidly. Additive Manufacturing
technologies offering product complexity for free but
demanding a new product design tailored for AM.
REFERENCES
Alec 2016, 3D Systems completes GE aircraft bracket
challenge with metal 3D printing solution,
www.3ders.org/articles/20160505-3d-systems-completes-ge-
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solution.html
Allen, J. 2015, An Investigation into the Comparative Costs of
Additive Manufacture vs. Machine from Solid for Aero Engine
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MP-AVT
Alvarez, P. 2014, Metal powder and Design Key elements for
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http://www.eos.info/werkstoffe-m
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