DMLS was originally developed to create complex cores and cavities and other geometries for the tooling industry. The initial machines and materials were quite advanced compared with other additive fabrication technologies on the market at that time; however, the technology was not the equal to more traditional methodologies such as CNC machining and spark erosion. Newer machines and continued material developments have propelled DMLS into being a dynamic and viable technology for many rapid tooling and low volume production applications.
The process generally begins with a designer or engineer going through a selection process for how the tool will be constructed. A myriad of factors come into play, such as leadtime, tool complexity, tolerances required, materials to be shot, and other criteria - many of which are factors that get considered with any decision-making process involving traditional tooling decisions. Once the designer has designated DMLS to be a viable route to take, a 3-D CAD model of the components (core, cavity etc) needs to be constructed.
It is important to take into account that designing the optimal tool for the DMLS process is very different than designing the same tool for more traditional methods. Volume and height of the inserts or components should be minimized as these tend to be time and cost drivers.
Once a 3-D CAD model has been developed, an .stl file is exported to the DMLS build software. Build parameters are checked and the build is initiated in the machine. Once completed, the build platform with the tooling inserts or components are removed from the steel platform and post operations, such as polishing and other traditional tooling steps, are performed on the components before they are mated up with other tooling items.
NB: Taken from an article written by Greg Morris for Moldmaking Technology (www.moldmakingtechnology.com/articles/0506additive.html)
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