DIY metal 3D printing: YouTuber relies on selective laser melting

Metal 3D printing has been considered difficult to access in the hobby sector for years. In a DIY project, YouTuber Travis Mitchell shows that the industrial approach of selective laser melting can also be implemented in a do-it-yourself environment with sufficient resources. Professional systems require high investments and complex peripherals. Nevertheless, the setup shown provides concrete insights into the technology and limitations of an independently implemented SLM system.

At the heart of the setup is an SLM system with a 500-watt fiber laser and a galvo scan head, which account for the majority of the costs. To prevent oxidation, the printing process operates in an inert atmosphere. The developer deliberately reduced the volume of the build chamber in order to lower argon consumption. The scan head is therefore located outside the chamber and directs the laser onto the powder bed through a window in the lid. Two pistons form the build platform and powder supply, driven by converted industrial servo motors. Another servo moves the squeegee, which distributes fresh metal powder after each layer.

The tests reveal typical challenges of the powder bed process. The first layer proved to be critical, as too high a laser power caused the powder to clump, while too little energy resulted in incomplete fusion. Precise focusing of the laser significantly improved adhesion. Nevertheless, heat input and the resulting distortions remained a key issue. The choice of squeegee also played a role. A plastic blade with a silicone edge initially used did not withstand contact with hot, molten metal. Switching to a stainless steel blade led to more stable and reproducible results.

The samples produced show clearly recognizable fused metal structures and reveal the fundamental potential of the structure.