EOS Has Developed a Solution for Support-Free Metal 3D Printing

Metal 3D printing today is primarily targeted at professionals. This opens up new opportunities for them in many industries. Grand View Research found that while the 2022 market value was $4.06B, it is expected to rise to $22.60B by 2030, according to a report. DMLS, which stands for Direct Metal Laser Melting, is a notable example. This process was first invented by EOS in 1994 and is used across all industries, including aerospace and medicine. It combines the benefits of metal 3D printing and high quality, repeatable parts.

Like other additive manufacturing technologies DMLS technology also requires support structures (supports). EOS developed a range solutions to enable metal 3D printing with complex geometries, while drastically reducing the number of support structures. Because supports in metal 3D printing can take more time, materials, and effort during post-processing,

Metal printing on an EOS quad laser system (photo credit: EOS GmbH).

The Challenges Associated with Support Structures for Metal 3D Printering

It is normal for DMLS users to need to add support depending on the part they are using. Because it’s only then that you can 3D print geometries with more intricate and detailed designs. This includes the creation of smaller overhangs than 30 degrees, complete bridges, or recesses within the component. These geometries will deform without support structures.

To overcome this problem, supports can be added to the design process. They then need to be removed manually after 3D printing or automatically. We can see that adding supports is required for many parts. But, they also present some problems which are reflected in the costs. 3D printing with metals is now possible thanks to the innovative DMLS process that allows for printing with a smaller number of support structures.

EOS Supports Customers Implementing Support-Free 3D Printering

Three factors are essential to ensure that you can also enjoy the benefits of 3D printing without support: the process, the tools, and the relevant know-how. EOS provides an excellent example of support-free DMLS3Dprinting using an impeller. Because of its complicated geometries, it normally relies upon support structures. Because each impeller is unique in terms of its diameter, number and cover, support-free printing can be more challenging. EOS states that it is essential to have the right knowledge and to communicate this information at all levels.

You need to think additively in order to make metal 3D printed with limited supports. This can be accomplished by a variety of training and consulting. This knowledge is crucial in areas such as design, layout and material. Smart Fusion is also an important piece in the puzzle of support-free metal 3-D printing. It should soon be made available to users. This tool adjusts laser energy to the geometry in question and can reduce thermal stress. Reduced support structures in metal-based additive manufacture can result in shorter build times and less effort in post-processing. This will also help you save material.

“Even though we are pushing the boundaries of what is possible in support-free 3D printing, you are still dealing with real physics and therefore not everything is possible. Our solution is a game-changer. We are both excited about the potential of the technology and so are our customers, both pilots and customers who have already tested it with us. I would say challenge us – we are ready to innovate metal 3D printing together,” Davy Orye, Additive Minds Consultants team leader, expands.

The impeller was made in an optimized 316L manufacturing process on an EOS M 290, without any internal supports. It also achieved a cost reduction (35%). (photo credit: EOS GmbH).

This is a result of the attractiveness of metal 3D printers and their support-free additive manufacturing. A cost analysis of the impeller shows that 35% could be saved. These savings are mainly in post-processing, material, and construction time. However, costs and effort to design a process without support structures went up from 8 to 14%. Additionally, 3D printing without support is more cost-effective and produces less waste. Users are not required to perform any post-processing such as cutting or grinding. This also makes the process safer. You can find all the details about support-free metal 3D printing HERE.

What do you think of the possibility of metal 3D printing using fewer support structures? Let us know in a comment below or on our LinkedIn, Facebook, and Twitter pages! Don’t forget to sign up for our free weekly Newsletter here, the latest 3D printing news straight to your inbox! You can also find all our videos on our YouTube channel.

*Cover Photo Credits: EOS GmbH (hip stems produced by optimizing the Ti64 process on an EOS M 300-4 for 100% support-free manufacturing).