Sinterstation. Pro Direct Metal SLM System

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1 Sinterstation Pro Direct Metal SLM System Jim Dier SLS and SLM Systems, Upper Midwest 3D Systems, Inc. 18 July 2008

2 Introduction Product overview Systems Sinterstation Pro DM100 SLM System Sinterstation Pro DM250 SLM System Materials Aluminum (aerospace) Titanium (medical/dental) Cobalt Chrome (dental) Stainless steel (parts) Tool Steel (tooling)

3 Direct Metal System Optics Laser Levelling System Inert Gas Part Part Laser Beam Powder Build Platform Note: Part requires support structure

4 Direct Metal System Sinterstation Pro DM100 SLM System Build volume: Ø 125 mm x 80 mm (Ø 5 inch x 3 inch) Typical build speed: 7-10 cm 3 /hour ( inch 3 /hour) Layer thickness: 30 or 50 micron (0.001 or inch) Laser type: 50 (air cooled) or 100 Watt (water cooled) infrared fiber Laser beam diameter: micron ( inch) Scan speed: up to 10 m/sec (400 inch/sec) External system dimensions: 1.0 x 1.0 x 2.4 meter Inert gas: nitrogen or argon Runs all metal materials (excl. aluminum)

5 Direct Metal System

6 Direct Metal System Sinterstation Pro DM250 SLM System Build volume: 250x250x250 mm (220 mm with heated build platform) 10x10x10 inch (8.7 inch) Typical build speed: 7-10 cm 3 /hour ( inch 3 /hour) Layer thickness: 50 or 75 micron (0.002 or inch) Laser type: 100, 200 or 400 Watt infrared fiber (water cooled) Laser beam diameter: micron ( inch) Scan speed: up to 10 meter/sec (400 inch/sec) External system dimensions: 1.4 x 1.9 x 2.5 meter (55x75x100 inch) Inert gas: nitrogen or argon Runs all metal materials

7 Direct Metal System

8 Direct Metal System cm 0.25 mm (0.01 inch) wall thickness

9 Direct Metal System Options: 50, 100, 200 or 400 Watt Infrared Fiber Laser Material Safety System/BOS Upgrades Required when operating titanium and aluminium Standard or Integrated Break-Out Station (BOS)

10 Direct Metal Materials Selective Metal Laser Sintering powders have been optimized for the process: Right shape Right size distribution (typically 10 to 45 micron, average 20 micron) Right properties No thermal pre-treatment 200 microns (0.008 inch)

11 Direct Metal Materials DuraForm materials: - Aluminium (aerospace) AlSi12Mg - Titanium (medical) Ti Al6 Nb7 Ti Al6 V4 Ti (pure, grade 1) - Cobalt Chrome (dental) CoCr ASTM F75 - Stainless steel (parts) / 316L - Tool Steel (tooling) / H13 Aluminium/titanium require argon gas atmosphere

12 Direct Metal Materials Mechanical properties (stainless steel ) vertical parallel standard steel data N/mm 2 [%] [N/mm] > 190 N/mm 2 > 40 % Offset yield stress Tensile strength Ductile yield 0

13 Direct Metal Materials Mechanical properties Ductile yield stainless steel

14 Direct Metal Materials Surface finish of a polished aluminum part

15 Direct Metal Materials Hardness > 52 HRC (Rockwell C) Stainless steel

16 Direct Metal Materials Excellent compression strength

17 Direct Metal Materials Density of stainless steel Run Number x D

18 Direct Metal Materials Scanning strategy impacts density (up to 99,8%)

19 Direct Metal Applications Rapid Manufacturing: Medical Dental Aerospace Automotive Educational/Government Tooling (conformal cooling): Injection Molding Die casting

20 Direct Metal Applications Medical: Jaw section and skull plate (Titanium Ti Al6 Nb7)

21 Direct Metal Applications Medical: Stainless steel surgical drilling guide (from CT Data)

22 Direct Metal Applications Medical: Rapid Manufacturing of Bone Replacement Structures CAD data from CT scan Create mesh structure within CAD data of bone

23 Direct Metal Applications Medical: Rapid Manufacturing of Bone Replacement Structures Manufacture mesh structure implant

24 Direct Metal Applications Medical: Rapid Manufacturing of Bone Replacement Structures Trabecular implant structure (CT scan) and titanium part Coated with Hydroxy Apatite (HA)

25 Direct Metal Applications Medical Biocompatibility (Titanium Ti6Al7Nb) Fluorescence microscope photos for cell adherence test (human lymphozytes and granulozytes cells). Green color identifies living cells and red ones show dead ones.

26 Direct Metal Applications Dental Caps, Crowns and Bridges (Cobalt Chrome or Titanium) Material: Cobalt chrome Layer thickness: 30 micron Units: 60 Build time: 5 hours 15 min Finishing/polishing: Cap 2 min. Crown 15 min. Bridge 2 min.

27 Direct Metal Applications Traditional dental caps, crowns and bridges production Gaumen / Gum Preparation Cleaning Pour Impression Gips Gips Silicone Impression Ceramic Casting Cap in Wax Keramik Ceramic Keramik Ceramic Keramik / Ceramic Keramik / Ceramic Casting Preparation Metal casting Finished Cap

28 Direct Metal Applications Rapid Manufacturing of dental caps, crowns and bridges Gaumen / Gum Preparation Cleaning Pour Silicone Gips Silicone Impression Create Casting Digital Scanning Software Preparation Rapid Manufacturing Finished Cap

29 Direct Metal Applications Aerospace windtunnel part

30 Direct Metal Applications Aerospace: Aircraft Nose Cone

31 Direct Metal Applications

32 Direct Metal Applications Conformal Cooling for Injection Molding Reduce cycle times and thermal stress

33 Direct Metal Applications Conformal Cooling for Injection Molding

34 Competitive Comparison Product Differentiation 1. Build speed 2. Materials: Aluminum/titanium and certain metal materials 3. Best feature definition and surface finish 4. Easier to remove support structures 5. Optional: Integrated breakout/recycling-station 6. Different machine build volumes

35 Thank You

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