ABSTRACT
This chapter explores the role and impact of direct metal laser sintering (DMLS) on rapid prototyping and, more importantly, the progression of 3D manufacturing/additive manufacturing (AM) as a disruptive advancement for design and production. Iteration drives the i3D MFG™ proof-of-concept as production model. Iterative solutions to DMLS design, material, parameter, process, and postprocess challenges are aimed at one goal: Refine and document until reaching the optimal, repeatedly manufacturable part with a corresponding DMLS design, parameter, and production recipe. DMLS enables engineers to revolutionize designs by erasing traditional design constraints and facilitating significant weight reduction strategies, material savings, assembly consolidations, and complex internal geometries to create exponential part efficiencies. The composition on the metal DMLS powder and the atmosphere to which it is exposed has considerable impact on the build and part success and density or porosity. Powder lots, laser power manipulations, and humidity all affect DMLS porosity.
