Selective Laser Melting and
Additive Manufacturing by BENSELER
SLM
Whether medical technology, prototype construction, small to medium series in the automotive industry or mold making: BENSELER has been supporting a wide range of industries in the innovative production of components using selective laser melting for over 10 years.
At BENSELER, you receive the all-round carefree package in production from 3D-Laser BW. This means that BENSELER and 3D-Laser BW together are full-service providers, from design to the ready-to-install component.
Whether conventional geometries, functional integration, cooling, media or air ducts in your component, BENSELER will find the perfect solution for you.
Find out more about selective laser melting below.
What is Selective Laser Melting?
With the help of selective laser melting, BENSELER builds components layer by layer based on 3D data for printing. To do this, metal is applied in powder form to a base plate and locally remelted by a fiber laser. After each layer, the plate lowers and new powder is applied - the cycle starts all over again. The finished component is built up layer by layer and can be used directly or further processed according to requirements.
Why Selective Laser Melting?
Selective laser melting can be used to customize your component. The process is
• Powder-bed-based
• Suitable for producing more delicate components
• Produces cooling channels from 0.5 mm in diameter
• Ideal for the production of smaller function-integrated components
BENSELER currently processes the following materials: 1.4404 1.4542, Inconel 625, Inconel 718, AlSi10Mg, 1.2709
Properties of Selective Laser Melting at a glance
The SLM process has numerous properties:
• High specific densities (> 99 %) of the processed material
• Mechanical properties of SLM components are comparable or in some cases better than those of conventionally machined parts
• Short product development time due to elimination of tool and mold making
• Weight-optimized
• Creation of conformal cooling for injection and die-casting tools possible
• Processing of high-strength aluminum alloys, stainless steels and special steels possible.
Advantages of Selective Laser Melting
The advantage of Selective Laser Melting over conventional production methods is that there is no need to develop and manufacture complex and cost-intensive tools and molds:
• Design of new, complex geometries and functions
• Untreated surfaces in investment casting quality
• Production of almost limitless component geometries
• Short production times
• Flexible production on site and as required
• Reduction of storage costs
• Hybrid design possible
• Tool-free working possible
• Sustainable process due to low material consumption
Areas of application for Selective Laser Melting
The process of selective laser melting is suitable for both prototype and series production and can be used in the automotive industry, aerospace, medical technology, racing, mold/tool making and mechanical engineering.
The process sequence of Selective Laser Melting
Find out more about the selective laser melting process below.
Step 1: Design and simulation
Once the data has been received, a feasibility check is carried out. On this basis, BENSELER offers the customer advice on the optimum procedure. The component is then optimized for selective laser melting. When the order is placed, the component is prepared for printing using 3D CAD and, if necessary, optimized and simulated for printing.
Step 2: Additive manufacturing
With selective laser melting, metal is applied in powder form to a base plate and locally remelted by a fiber laser. Layer after layer is welded together using a laser. After each layer, the plate is lowered and new powder is applied - the cycle starts all over again. This is done automatically based on the pre-generated data of the desired 3D model.
Step 3: De-powdering and de-supporting
Once the excess powder has been removed and the finished component has been separated from the base plate and freed from the support geometries, it can be used directly or further processed according to requirements.
Step 4: Machining
The part is then optionally processed using heat treatment, CNC machining, polishing and/or grinding. Surface treatment is also possible on request.
Additional services for Selective Laser Melting
In addition to selective laser melting, BENSELER offers you the following services:
• Constructive support and design of e.g. conformal cooling
• CNC machining for the functional integration of your SLM parts
• Assembly of components
• CNC machining of pure prototypes
• Optoelectronic checks
• Heat treatment processes
Other special services such as coating are available upon request.