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DMLM – Direct Metal Laser Melting

Fathom is a service provider of Direct Metal Laser Melting (DMLM), the latest technology for 3D printing and additive manufacturing of 3D printed metal parts. Fathom produces 3D metal parts for applications ranging from prototypes to production. DMLM technology is ideal for a variety of applications including the creation of conformal cooling channels for injection molding tooling. DMLM is commonly known by the acronym DMLS for Direct Metal Laser Sintering.

Utilizing the DMLM process, metal parts of the most complex geometries are built layer-by-layer (down to 20 microns) directly from 3D CAD data. Parts built using DMLM have excellent mechanical properties equivalent to wrought materials, high detail resolution, and exceptional surface quality. The metal powder is melted entirely to create a fully dense, fine, homogenous structure. Unique geometric freedom of design enables DMLM to form cavities and undercuts, which with conventional machining methods, can only be produced with great difficulty—if at all.

When a part needs to be tested and re-designed over and over, the lead time for receiving a traditionally tooled part can create a large bottleneck in the final production process. DMLM produces parts that are extremely high quality and can be built in a matter of hours or days rather than weeks. The ability to generate functional metal prototypes in short order radically impacts design processes, accelerating design cycles and time to market.

Depending on size and geometries, the turnaround time for a part can be as little as a few hours. These parts are highly functional and can undergo real-world testing in the environment for which they were designed. This technology delivers unlimited potential for engineers to create previously impossible solutions, embracing a new era of design-driven manufacturing.

Fathom utilizes a variety of machines from EOS including the EOSINT M 270, the EOSINT M 280 and the EOSINT M 290.

 

DMLM Materials & Specifications

 

MATERIAL ALLOY DESIGNATION LAYERS HARDNESS ADVANTAGES APPLICATIONS
Stainless Steel (PHI) 15-5 PH, DIN 1.4540 & UNS S15500 20 or 40 Micron Layers 30-35 HRC Built, Post Hardened to 40 HRC High Hardness & Strength Prototype / Production Parts
Stainless Steel (GPI) 17-4, European 1.4542, German X5CrNiCuNb16-4 20 or 40 Micron Layers 230 ± 20 HV1 Built, Ground & Polished to 250-400 HV1 High Toughness & Ductility Engineering Applications
Cobalt Chrome (MPI) ISO 5832-4 & ASTM F75 20, 40 or 50 Micron Layers 35-45 HRC Built High Temperature Resistance Turbines & Engine Parts
Maraging Steel (MSI) 18% Ni Maraging 300, European 1.2709, German X3NiCoMoTi 18-9-5 20 or 40 Micron Layers 33-37 HRC Built, Post Hardened to 50-56 HRC Easily Machinable & Excellent Polishability Injection Molding Tooling, Conformal Cooling
Aluminum AlSi10Mg Typical Casting Alloy 30 Micron Layers Approx 119 ± 5 HBW Low Weight, Good Thermal Properties Automotive, Racing
NickelAlloy IN718 UNS N07718, AMS 5662, AMS 5664, W.Nr 2.4668, DIN NiCr19Fe19NbMo3 40 Micron Layers 30 HRC Built, Post Hardened 47 HRC Heat & Corrosion Resistant Turbines, Rockets, Aerospace
Stainless Steel (316L) ASTM F138 20 Micron Layers 85 HRB Corrosion & Pitting Resistant Surgical Tools, Food & Chemical Plants
Titanium Ti-64 * ASTM F2924 30 or 60 Micron Layers 320 ± 15 HV5 Light-Weight, High Strength, Corrosion Resistant Aerospace, Motorsport Racing
Titanium Ti-64 ELI * ASTM F136 Properties 30 or 60 Micron Layers 320 ± 15 HV5 Corrosion Resistance, Biocompatibility Medical, Biomedical, Implants

* Please contact expert@fathommfg.com for more information.

 

 

If you are looking for a fast turnaround on metal parts with excellent mechanical properties, high resolution and exceptional surface quality, talk to a Fathom expert to quote your next project.

Comprehensive Capabilities for Rapid Manufacturing

At Fathom we offer a unique advantage of speed and agility-our experts help companies go from concept to prototype to manufacturing in ways not previously possible. 

90+ Machines  
SLS / / Two-day  SLA / / Next-day 
FDM / / Next-day DMLS / / Three-day 
PolyJet / / Same-day MJF / / Two-day
   

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30 Second Quotes
Prototype Tool / / As soon as 10 days
10K Parts / / 10 days
Production Tool / / As soon as 3 weeks
 

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3 & 5 Axis Milling & Turning
(Plastics, Composites and Metals)

Tolerance Accuracy Range
from +/-0.001″ to 0.005″

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Injection Molding Adjacent
without High Costs of Metal Tools

Most Commonly Used for High-Volume
Prototyping & Bridge to Production

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Finishing, Production Painting and Color Matching

Assembling, Including Embedded Electronic
Components, Threaded Inserts, and More

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CAD, DFAM and DFM Services

Apply Methods to Increase Speed
and Decrease Total Cost

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Highly Trained Staff / / Full-Time & Part-Time
Support as Short-Term & Long-Term Strategy

Decrease Downtime with Customizable
Staffing Accelerates Implementation

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Fathom is driven by advanced technologies and methods that enhance and accelerate today’s product development and production processes.

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