Direct Metal Laser Sintering (DMLS)

3D Designs to Production-Quality Metal Parts in Hours

DMLS is an ”additive” technology that works by sintering very fine layers of metal powders layer-by-layer from the bottom up until the build is complete. The process begins by sintering a ”first layer” of 20 micron (0.0008") powder onto a steel platform. The platform then lowers by 20 microns, a fresh layer of powder is swept over the previously sintered layer and the next layer is sintered on top of the previously built one. A powerful 200W Yb-fibre laser is precisely controlled in the X and Y coordinates allowing for exceptional tolerances to be held (+/-0.001"/inch)(0.0254 mm). The latest technology takes advantage of a ”dual spot” laser allowing feature sizes as small as 0.203mm to be built. With a machine build envelope of 250 x 250 x 215mm (9.84" x 9.84" x 8.46"), many medium to small parts and inserts can be constructed in hours and days versus days and weeks using traditional processes. Once started, the machine builds unattended, 24 hours a day. Parts and inserts that come out of the machine typically will go through a series of ”post” steps, including support removal, shot peening, etc.

World's Largest DMLS Capacity

Morris Technologies was the first company in North America to acquire this technology in 2003. Since then, we have purchased additional machines and are currently North America's leading supplier of DMLS parts and inserts. With five (5) alloys currently available, including the Super Alloy Cobalt Chromium (CoCr) and Stainless 17-4 PH, Morris Technologies remains at the leading edge of this advanced technology. Applications are wide ranging and include inserts for plastic injection molding and die casting, as well as direct parts for a variety of applications and industries, including Aerospace, Automotive, Medical, Electronics and many others.

Morris Technologies has seen the technology used primarily for smaller, complex parts that would be time consuming and expensive to make using other, more traditional methodologies.

New Developments

New alloys are constantly in development, including Titanium and Inconel 718.

Capabilities

  • Rapid injection mold tooling
  • Rapid metal parts
  • Extremely fine detail resolution with 20 micron layers (0.0008") and ”dual spot” laser to achieve feature details down to 0.203mm (0.008")
  • Highly accurate (+/-0.001"/inch)(0.0254 mm)
  • Multiple alloys, including super alloys such as CoCr and Stainless 17-4 PH
  • Fully dense parts using CoCr and 17-4 Stainless

Materials Information

EOS' e-Manufacturing Partner

As an EOS' e-Manufacturing Partner, Morris Technologies is one of four e-MP companies worldwide, with a specific emphasis on the DMLS technology. This strategic partnership with EOS will help advance Direct Metal Laser Sintering technology and materials, and is an indication of our global leadership position within this high-tech industry. The e-Manufacturing partnership objectives consist of:

  • Identify, implement and spread applications suitable for laser sintering as a mode of manufacturing across industries using the DMLS process.
  • Consult and aid customers on how to implement an economically feasible manufacturing process based on metal laser sintering.
  • Identify possible applications and initiate implementation projects.
  • Promote awareness of the technology and the inherent advantages of using it for a variety of applications.

As an EOS' e-Manufacturing Partner, Morris Technologies will continue to invest both in the technology itself as well as associated infrastructure necessary to take the technology to new levels.