Powder Bed Fusion: Difference between revisions

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== Process description ==
== Process description ==
Although it can use a number of different materials the main use of powder bed fusion is being a convenient way to print metal parts. spreading a layer a powdered material over the entire print surface, and then selectively melting the sections that will be in the final part. another layer is then added on top of the last repeating the process until the part is completed.
[[File:PXL 20230828 231728663.jpg|right|frameless|422x422px]]
Powder bed fusion is primarily used to build metal parts, although other materials may be used. Powder bed fusion works by spreading a layer of powdered material over the entire print surface and then using a laser to selectively melt sections together. Another layer is then added on top of the last and the process is repeated until the part is complete. After the part is built, it must be thoroughly cleaned and scrubbed to remove excess powder.  
==Strengths & Weaknesses==


== strengths ==
=== Strengths ===
*'''Built in support system:''' The excess powder supports the print so there's no need to add printed supports, enabling the building of more complex geometries while maintaining consistent surface finish throughout the part.
* '''Small footprint''': Powder bed fusion machines frequently have a small footprint, and can be added into most workplaces. This allows for organizations to create metal prototypes in house.


* '''built in support system:''' The excess powder supports the print so there's no need to add printed supports
=== Weaknesses ===
* '''in house metal components''': PBF can  be small enough to fit into a variety of spaces. this allows for organizations to create metal prototypes 
*'''High energy use:''' Melting metal with a laser takes significant energy.
* '''Surface finish:''' Powder bed fusion generally has a rough surface finish.
* '''Material properties:''' This process produces a weaker grain structure compared to parts cast from the same material.


== weaknesses ==
[[File:PXL 20230828 232002915.jpg|right|frameless|421x421px]]
[[File:PXL 20230817 210159504.jpg|right|frameless|421x421px]]


* '''High energy use:''' melting metal takes much more energy then melting thermoplastics.
== Machine Ranges ==
* '''Surface finish:''' Powder bed fusion generally has a rough surface finish that mimics the grain size of the material.
 
* '''material properties:''' the way that parts are formed creates a weaker grain structure then a cast part made out of the same material.
Overall, this technology can produce smaller parts with high dimensional accuracy. Powder bed fusion printers are on the more expensive side and require quotes from individual companies. Our research indicates these machines are on the order of $1,600,000.
{| class="wikitable"
{| class="wikitable"
!
!
!Low
!Worst
!High
!Best
|-
|-
|volume X/Y/Z (mm)
|volume X/Y/Z (mm)
|
|250/250/325
|
|800/400/500
|-
|-
|resolution (mm)
|resolution (mm)
|
|.1
|
|.06
|-
|-
|layer height (um)
|layer height (um)
|
|120
|
|20
|-
|-
|price ($)
|price ($)
|
|Requires
|
|Quotes
|-
|Weight(kg)
|4635
|1060
|-
|Build rate (cm^3/hr)
|20
|120
|}
[[File:Dmp-flex-350.webp|none|thumb|[https://www.3dsystems.com/3d-printers/dmp-flex-350 Dmp-flex-350]]]
{| class="wikitable"
!Build volume
!layer Height
!resolution
!size xyz
!Price
!Weight
|-
|275/275/420mm
|60um
|.005mm
| 2370/2400/3470mm
|Requires Quote
|4200
|}[[File:SPro 230.webp|none|thumb|[https://support.3dsystems.com/s/3d-printers/spro-140-and-230?language=en_US SPro 230]<nowiki/>]]
 
{| class="wikitable"
!Build Volume
!Layer Height
!Resolution
!Size xyz
!Power
!Price
!Weight
|-
|256/256/256mm
|50um
|.2mm
| 386/389/458mm
|350W
|Requires Quote
|2541
|}
|}
== Technologies ==
== Technologies ==
There are a number of specific technologies that can vastly change to capabilities of a printer.
There are two main classes of Powder Bed Fusion printers that describe the laser process and typically indicate the type of materials it uses.
 
'''Selective Laser Sintering (SLS)''': This is the general term for non-metal powder bed fusion technologies. The term indicates that the heat source only adds enough energy to fuse the powder instead of fully melting it. SLS printing can provide improved capabilities when compared to material extrusion for softer materials such as as nylon or softer thermoplastics.
 
'''Selective Laser Melting (SLM)''': In contrast to SLS, SLM refers to processes of metal powder bed fusion. The energy added completely melts the material, making the internal structure more homogenous. This technique produces fully metal prototypes relatively easily.
 
==Navigation==
*[https://omic-am.mme.pdx.edu/index.php/Main_Page?veaction=edit Home page]
*[[Material extrusion|Material Extrusion]]
*[[Powder Bed Fusion]]
*[[Vat Polymerization]]
*[[Direct Energy Deposition]]
*[[Binder Jetting]]
*[[Material Jetting]]
*[[Sheet Lamination]]
 
==References==
Rosen, Stucker, and Khorasani, Additive Manufacturing Technologies, chap. 5.
 
“Powder Bed Fusion - DMLS, SLS, SLM, MJF, EBM | Make.” Accessed October 6, 2023. <nowiki>https://make.3dexperience.3ds.com/processes/powder-bed-fusion</nowiki>.

Latest revision as of 08:06, 16 October 2023

Process description

PXL 20230828 231728663.jpg

Powder bed fusion is primarily used to build metal parts, although other materials may be used. Powder bed fusion works by spreading a layer of powdered material over the entire print surface and then using a laser to selectively melt sections together. Another layer is then added on top of the last and the process is repeated until the part is complete. After the part is built, it must be thoroughly cleaned and scrubbed to remove excess powder.

Strengths & Weaknesses

Strengths

  • Built in support system: The excess powder supports the print so there's no need to add printed supports, enabling the building of more complex geometries while maintaining consistent surface finish throughout the part.
  • Small footprint: Powder bed fusion machines frequently have a small footprint, and can be added into most workplaces. This allows for organizations to create metal prototypes in house.

Weaknesses

  • High energy use: Melting metal with a laser takes significant energy.
  • Surface finish: Powder bed fusion generally has a rough surface finish.
  • Material properties: This process produces a weaker grain structure compared to parts cast from the same material.
PXL 20230828 232002915.jpg
PXL 20230817 210159504.jpg

Machine Ranges

Overall, this technology can produce smaller parts with high dimensional accuracy. Powder bed fusion printers are on the more expensive side and require quotes from individual companies. Our research indicates these machines are on the order of $1,600,000.

Worst Best
volume X/Y/Z (mm) 250/250/325 800/400/500
resolution (mm) .1 .06
layer height (um) 120 20
price ($) Requires Quotes
Weight(kg) 4635 1060
Build rate (cm^3/hr) 20 120
Dmp-flex-350
Build volume layer Height resolution size xyz Price Weight
275/275/420mm 60um .005mm 2370/2400/3470mm Requires Quote 4200
SPro 230
Build Volume Layer Height Resolution Size xyz Power Price Weight
256/256/256mm 50um .2mm 386/389/458mm 350W Requires Quote 2541

Technologies

There are two main classes of Powder Bed Fusion printers that describe the laser process and typically indicate the type of materials it uses.

Selective Laser Sintering (SLS): This is the general term for non-metal powder bed fusion technologies. The term indicates that the heat source only adds enough energy to fuse the powder instead of fully melting it. SLS printing can provide improved capabilities when compared to material extrusion for softer materials such as as nylon or softer thermoplastics.

Selective Laser Melting (SLM): In contrast to SLS, SLM refers to processes of metal powder bed fusion. The energy added completely melts the material, making the internal structure more homogenous. This technique produces fully metal prototypes relatively easily.

Navigation

References

Rosen, Stucker, and Khorasani, Additive Manufacturing Technologies, chap. 5.

“Powder Bed Fusion - DMLS, SLS, SLM, MJF, EBM | Make.” Accessed October 6, 2023. https://make.3dexperience.3ds.com/processes/powder-bed-fusion.

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