Additive Manufacturing

What is AM?

AM, or Additive Manufacturing, is a manufacturing technology, also known as 3D printing, which involves creating parts by combining material layer by layer - as opposed to traditional subtractive technology, where the target element is manufactured by removing the surplus with cutting tools (e.g. milling, turning).

DMLS

Direct Metal Laser Sintering

One of the most advanced metal additive manufacturing methods is Laser Powder Bed Fusion (LPBF), which relies on selectively melting thin layers of metal powder using a high-energy laser beam. The commonly used industry term for this technology is SLM (Selective Laser Melting), while in our operations we employ the DMLS (Direct Metal Laser Sintering) process - a designation introduced and exclusively applied by EOS, the manufacturer of our printing systems.

Principle of Operation

Inside the build chamber, under a protective gas atmosphere, a thin layer
of metal powder is spread across the build platform. A laser beam scans along a path generated from the 3D model, selectively melting the material in the designated areas. Once a layer is completed, the platform lowers
by the layer thickness and a new layer of powder is applied. Repeating this cycle powder deposition followed by selective melting - gradually reproduces the entire geometry of the part.

This method enables the manufacturing of highly complex geometries unachievable with conventional techniques, while ensuring parts with exceptional dimensional accuracy, repeatability, and uniform mechanical properties.

A characteristic feature of the technology is the use of support structures, which stabilize the part during the build and allow for controlled heat dissipation. After printing, components are separated from the build platform, while unused powder is recovered and prepared for reuse.

Aluminium alloys

Used in general structural applications requiring considerable strength while maintaining low weight, corrosion resistance and thermal conductivity.

Tool steel

They are suitable not only for tool applications, but also for a wide range of components requiring unmatched strength.

Stainless steel

They guarantee the best properties in aggressive environments where components are exposed to corrosion and premature wear.

Nickel alloys

They are used in a wide range of solutions, from gas turbines in the space and energy industries to the oil and gas and shipbuilding industries.



Titanium alloys

Due to its material properties, titanium is used in the most demanding industries such as space, motor sports and medicine.

Copper alloys

Copper has excellent thermal and electrical conductivity, which is why it is used in everything from small coils and radiators to large-sized combustion chambers in rocket engines.

SLS

Selective Laser Sintering

SLS (Selective Laser Sintering) is a technology that allows for the rapid production of polymer components. Unlike DMLS or SLM, this technology is based not on melting but on sintering powdered polymer (most often PA or TPU). The sintering process is carried out layer by layer until the intended geometry is fully reproduced, similarly to DMLS/SLM.

The SLS method differs from other technologies primarily in its printing speed and very high design freedom, due to the absence of supports. The sintered material is light enough that the surrounding powder itself serves as a supporting medium. Most of the powder is recovered in an isolated chamber with a vibrating sieve, which separates the sintered fractions from those that can be reused in the next build. This method is highly economical, which is reflected in product costs.

Nylon PA 12

A basic and economical polyamide for rapid printing, combining chemical resistance with satisfactory strength. Available in graphite grey and white, with the option of dyeing.

Nylon PA 12 Tough

A stronger and more durable version of PA 12, intended for parts requiring higher reliability and durability.



Nylon PA 11 CF

A high-strength material reinforced with carbon fiber, characterized by high stiffness and dimensional stability.



TPU

An elastomer with high elasticity and very high abrasion resistance, used in the production of parts intended for vibration damping and sealing.

FDM

Fused Deposition Modeling

FDM (Fused Deposition Modeling) is an additive manufacturing technology from the Material Extrusion group, which consists of layer-by-layer deposition of molten thermoplastic material. The material in the form of filament is fed into the extruder, where it is heated, then extruded through a nozzle and applied to the build platform as successive layers. Repeated deposition of the material leads to the creation of the complete geometry of the model.

The process is based on precise control of temperature, material feed, and the movement of the print head, which ensures stable and repeatable results. For more complex geometries, support structures are used, which are mechanically removed after printing.

The FDM technology is widely used in rapid prototyping as well as in the production of end-use components. It is characterized by the lowest manufacturing cost, broad material availability, and flexibility - from simple conceptual models to fully functional parts

PLA

Advantages: common, biodegradable, low shrinkage, wide color range.
Disadvantages: low resistance to temperature and UV, brittleness.
Applications: prototypes, decorations, concept models.

ABS

Advantages: durable, heat-resistant, more flexible than PLA.
Disadvantages: high shrinkage, dimensional deviations, poor chemical resistance.
Applications: mechanical parts, housings, end-use parts.

PETG

Advantages: resistant to water, chemicals, and impacts.
Disadvantages: may be more flexible than desired in some applications.

Applications: containers, outdoor elements, functional parts.e

TPU

Advantages: flexible, abrasion-resistant, durable.
Disadvantages: more difficult to print, risk of imperfections.
Applications: seals, cases, flexible elements.

Nylon (PA)

Advantages: very strong, flexible, abrasion-resistant.
Disadvantages: absorbs moisture from the air, requires high nozzle temperature.
Applications: mechanical parts, gears, tools.

ASA

Advantages: UV- and heat-resistant, durable, properties similar to ABS.
Disadvantages: high shrinkage, dimensional deviations, poor chemical resistance.
Applications: outdoor-use parts.