German AM specialist EOS first revealed it had developed a brand new strategy to selective laser sintering (SLS) again in 2019. On the time, we bear in mind studying concerning the new expertise, known as Effective Element Decision (FDR), which made the thrilling promise of providing “the detailed decision of stereolithography with the sturdiness and high quality of selective laser sintering.” Just a few years on, and EOS’ FDR expertise is now established in the marketplace within the FORMIGA P 110 FDR system, and it is rather a lot delivering on these guarantees.
What FDR presents
EOS’ FDR expertise isn’t 1,000,000 miles away from SLS: each applied sciences make the most of lasers to fuse powder particles of polymer powder, build up elements layer by layer. The place FDR units itself aside is in the usage of CO lasers (versus CO2 lasers, that are the frequent choice for SLS platforms). CO lasers are able to producing ultra-thin beams of about 200 µm, which EOS factors out is about “half the scale of what’s seen in SLS 3D printers.” This smaller laser dimension has a direct impression on what customers can obtain of their prints, significantly in terms of effective particulars, skinny partitions and small options like lettering and microelectric connectors.
The CO laser is barely part of the FDR equation (albeit an enormous one), the expertise additionally depends on a extremely exact recoater, which distributes effective layers of powder quickly (at a charge of 600 mm/s) and with even density. The mix of the CO laser and the recoating system have resulted in a dimensional accuracy of +/- 40µm, similar to that of injection molding and SLA 3D printing.
On high of which are all the advantages usually related to laser powder mattress fusion processes, equivalent to supportless builds (because the powder mattress capabilities as a help). This considerably simplifies post-processing for FDR prints, in addition to streamlines the design course of and reduces materials waste. Briefly, elements are prepared to be used after cooling and depowdering, although extra post-processes like coatings and vapor smoothing are attainable.
Like SLS, FDR can be nicely outfitted for manufacturing volumes because of its fast sintering, minimal post-processing and the flexibility to nest a number of elements in a single construct. That is the place the expertise presents a definite edge over resolution-matching resin applied sciences. As EOS says: “The 3D printing strategies that may match FDR for element decision, like SLA and DLP, can’t approximate its manufacturing quantity: That is due largely to the gradual construct processes of those resin-based strategies, which the comparatively fast laser sintering of FDR can simply outpace.”
FDR in the marketplace
Finish customers can leverage Effective Element Decision expertise by adopting the FORMIGA P 110 FDR 3D printer, a compact industrial system specialised within the manufacturing of small, fine-detail elements. The machine has a construct quantity of 200 x 250 x 330 mm and integrates two 50 W lasers every with a wavelength of 5 um. These ultra-fine lasers generate a spotlight diameter of 200 µm, which allows the creation of partitions and options of that dimension—EOS studies that is about half the scale of different SLS 3D printing capabilities.
Up to now, EOS has certified a polyamide 11 (PA 11) powder to be used on the FORMIGA P 110 FDR 3D printer, which is characterised by a smaller grain dimension than commonplace SLS powders. The nylon materials is very versatile, providing a mix of excessive impression resistance, excessive elongation at break, sturdiness and chemical resistance. On high of those mechanical properties, the fabric is each recyclable and constituted of a renewable useful resource (castor beans, that are usually grown on land not match for meals crops). The printer’s recoater can distribute this PA 11 powder on the print mattress at a layer thickness of 40 µm. In keeping with EOS, different supplies are nonetheless being developed for its FDR answer.
The 3D printer can be designed for seamless integration into manufacturing services and store flooring because of its comparatively small footprint (1320 x 1067 x 2204 mm) and workflow software program. In keeping with EOS, the system has carried out remarkably nicely by way of reliability, overcoming points usually related to reaching such a effective print decision on powder-based platforms.
Functions for FDR
With “effective element” within the title, it’s no shock that EOS’ FDR expertise is ideally suited to the manufacturing of small elements with tiny options and complicated particulars. Generally phrases, the LPBF expertise may be utilized throughout just about any trade for functions like electronics elements and housings, effective filigree constructions like filters, and multi-part assemblies.
In a latest webinar, EOS AM knowledgeable Sebastian Frank highlights some particular functions the place FDR generally is a sport changer, equivalent to high-frequency antennae and microwave elements. The design freedom and have dimension unlocked by FDR printing make it attainable to provide thin-walled elements that may function at frequencies within the vary of 100 GHz. For all these functions, it’s attainable to use a galvanic coating to the PA 11 prints to provide them the mandatory conductive properties. This functionality is good for high-frequency functions, together with radar programs, autonomous driving elements, communication programs and extra.
The expertise has additionally been efficiently used within the manufacturing of multi-component assemblies that profit from excessive precision and dimensional accuracy. For instance, the FORMIGA P 110 FDR efficiently printed a personalized bicycle mild housing constituted of two elements that match collectively completely utilizing a cantilever snap match. Different connecting options that require excessive precision, like non-assembly hinges, movie hinges, screws and threads, and interlocking elements can be printed (even at a miniature scale) utilizing EOS’ FDR expertise.
The particular properties of PA 11 additionally open up sure functions for FDR. As an example, the fabric is biocompatible and might thus be used for medical functions, like fluid guides, and for elements that come into contact with meals. PA 11 can be low-friction, which together with the high-quality floor finishes of FDR prints permits for elements like bearing balls and planetary gears for electrical drives to be printed. Moreover, tiny options like embossed or debossed lettering can be built-in seamlessly within the unique CAD design. FDR can even have essential functions in design fields for the manufacturing of bijou with intricate particulars and even polymer-based textiles for wearables.
Finally, EOS’ Effective Element Decision expertise has introduced one thing new to the desk by combining ultra-fine printing capabilities with the effectivity and scalability of SLS. To study extra about FDR and particularly about designing for the high-precision course of, seek the advice of EOS’ FDR DfAM eGuide.