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What is Powder Bed Technologies Process?

Technologies such as Selective Laser Sintering (SLS), Selective Laser Melting (SLM), Direct Metal Laser Sintering (DMLS), and Electron Beam Melting (EBM) are some of the well-known names available in the market in this category.  Polymers, metals, and ceramics are materials commonly used in these technologies, and in all of them, fine powders are used to manufacture the part.  The energy source, i.e., laser or electron beam as shown in Fig. 1, impinges the layer according to the cross-section melts or sinters the thin layer of powder to the previously consolidated layers.  When the entire layer is scanned, a fresh new layer of powder with a thin thickness is spread and leveled at the top using a rolling mechanism, similar to one illustrated in Fig. 1, or a raking mechanism, and the process continues until the final layer.  Post-processing is an essential part of this method for enhancing sintering, removing pores, improving quality, and reducing the residual stresses in manufactured parts.  The processes that use metal powder work under vacuum or the presence of inert gases to protect the part against oxidation.   

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Fig. 1. Selective Laser Sintering (SLS) or Melting (SLM) technology for manufacturing fully dense components with high strength. The system consists of laser sources, scanning device, fabrication platform, powder delivery system, and powder distribution system which is installed in a vacuum or an inert environment to protect the product against oxidation. (image from Wikipedia.com)

Metal Powder Bed Additive, Source: GE.com

Polymeric Powder Bed Additive, Source: Formlabs.com

Technologies such as Selective Laser Sintering (SLS), Selective Laser Melting (SLM), Direct Metal Laser Sintering (DMLS), and Electron Beam Melting (EBM) are some of the well-known names available in the market in this category.  Polymers, metals, and ceramics are materials commonly used in these technologies, and in all of them, fine powders are used to manufacture the part.  The energy source, i.e., laser or electron beam as shown in Fig. 1, impinges the layer according to the cross-section melts or sinters the thin layer of powder to the previously consolidated layers.  When the entire layer is scanned, a fresh new layer of powder with a thin thickness is spread and leveled at the top using a rolling mechanism, similar to one illustrated in Fig. 1, or a raking mechanism, and the process continues until the final layer.  Post-processing is an essential part of this method for enhancing sintering, removing pores, improving quality, and reducing the residual stresses in manufactured parts.  The processes that use metal powder work under vacuum or the presence of inert gases to protect the part against oxidation.   

Selective laser melting (SLM), Source: DMGMORI.com

Direct Metal Laser Sintering (DMLS), Source: EOS.info

Electron Beam Melting (EBM), Source: GE.com

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