Another class of printers relies on depositing feedstock directly into a molten pool, as opposed to selective melting of a powder bed. Binder Jetting can be used to create metal parts, in addition to other materials. The use of ‘3D printing’ has evolved in popular media to describe all forms of AM, while the MIT method has become known as Binder Jetting. Shortly after SLS was patented, a group of researchers at MIT patented a process called ‘three-dimensional printing’, which used inkjet printing to deposit binder. This process is under licence by EOS GmbH, though other companies have entered the market with laser powder-bed hardware for metal production (SLM Solutions, Concept Laser, Renishaw, 3D Systems). The term SLM is used throughout this work to refer to all metal powder-bed processes that use a laser as a heat source. Metal powder-bed processes have been called SLM, direct metal laser sintering, etc.
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Today, systems used to make metal parts are typically referred to by selective laser melting (SLM) because full melting of the metal powder is achieved, whereas the term SLS is typically used to refer to polymer powder-bed processes only. Bourell: ‘Selective laser sintering of binary metallic powder’, in ‘Solid freeform fabrication symposium’, Austin, TX, 1990, 99–106. Arguably, the first reported metal ‘3D printed’ part was made from metal alloy powders (copper, tin, Pb–Sn solder) in an SLS process in 1990 by Manriquez-Frayre and Bourell. One of the earliest prototypes of SLS, ‘Betsy’, integrated the first automated powder distribution system. This research focused on powder-bed laser sintering, which was patented and copyrighted as selective laser sintering (SLS). Crawford: ‘Challenges in laser processed solid freeform fabrication’, Processing and Fabrication of Advanced Materials III, proceedings of the 1993 TMS materials week conference, Pittsburgh, PA, 17–21 October 1993, 127–133. Beaman: ‘ Selective laser sintering of metals and ceramics’, Int. Deckard: ‘Selective laser sintering’, PhD thesis, Univeristy of Texas, Austin, TX, 1988.ĭ. Grosvenor: ‘Selective laser sintering, birth of an industry’, 2012. The first experiments directly relevant to metal AM started by forming polymer powder into 3D parts. Understanding the various processes used to make metal AM parts, and the issues associated with them, is critical to improving the capabilities of the hardware and the materials that are produced. The development of metal AM techniques has made great progress since then, but faces unique processing and materials development issues. Deckard: ‘Part generation by layer-wise selective laser sintering’, MS thesis, Univeristy of Texas, Austin, TX, 1986. Additive manufacturing (AM), also known as three-dimensional (3D) printing, has grown and changed tremendously in the past 30 years since researchers in Austin, TX, started development of what is arguably the first machine in the lineage of metal AM: a laser used to selectively melt layers of polymer and, later, metal.
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