Design guidelines for metal 3D printing: optimization of DMLS components

The additive manufacturing of metal components has become established in many industries. Direct metal laser sintering (DMLS) in particular enables the production of complex geometries with a high level of detail. Despite the advantages of this technology, there are design challenges that can affect the quality and stability of the printed parts. A well thought-out design strategy can avoid errors and optimize the production process.

A decisive factor in DMLS is the consideration of support structures. These are necessary to stabilize overhangs and complex geometries during the printing process. Components with angles below 45 degrees usually require additional support, which increases material consumption and post-processing time. Clever alignment and the integration of self-supporting structures can reduce this effort.

Wall thickness also plays an important role. Walls that are too thin can lead to deformations or structural weaknesses. In general, load-bearing walls should have a minimum thickness of 1.2 millimeters to ensure stability. In addition, the diameter of holes and channels should be chosen so that no powder residues remain trapped. A drop-shaped design of such structures facilitates powder removal.

Particularly critical aspects are narrow gaps and neighboring structures. If the distance between moving components is too small, there is a risk of fusing during printing. A minimum gap of 0.5 millimeters is required to ensure a clean separation of the elements. At least 0.3 millimeters should be planned for press fits.

Another design feature is the integration of escape holes in hollow components. These holes allow the unsintered powder to be removed from internal cavities and should be at least 2 to 5 millimetres in diameter. Their placement on non-visible surfaces facilitates post-processing and improves the visual quality of the end products.

Optimizing the geometry is crucial for the successful use of DMLS. By adhering to proven design guidelines, material usage, post-processing effort and production times can be minimized while improving the quality and durability of the components.

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