Home > Additive Manufacturing

Additive Manufacturing

Rapid Manufacturing using Selective Laser Sintering (SLS) and Direct Metal Laser Sintering (DMLS) technologies

Selective Laser Sintering (SLS)

Operating the largest SLS capability for rapid manufacturing in the UK, we produce functional metal prototypes and aesthetic models with the best surface finish and mechanical properties that the technology can provide, in the shortest lead-times possible.

Complexity of design and geometry is irrelevant when using SLS technology for rapid prototyping, therefore intricate details can be easily replicated and previously 'impossible' structures and forms created.

SLS Model of the Free University, Berlin built in one piece in Nylon by 3T for Foster + Partners

SLS is a rapid prototyping process of fusing together layers of powder (eg. Nylon and Glass Filled Nylon) into a 3D model by a computer-directed heat laser.

Take a look at our SLS section to find out more about this rapid manufacturing technology.

SLS Machines

Uniquely able to offer rapid prototypes built on both EOS and 3D Systems machines, our suite includes some of the world's largest SLS machines - three EOS P730's, two EOS P380's and a 3D Systems HiQ 2500 Plus - thus enabling us to provide the optimal machine to meet our customers' requirements.

As part of the rapid manufacturing process, large parts can be built in a single piece up to a build volume of 700x380x580mm on the P730's; the reduced need for joints and post-assembly dramatically increases their functionality. The P380's allow parts to be built up to 620x340x340mm, and smaller parts with finer detail can be produced on the HiQ 2500 Plus.

Find full SLS Machine Specifications

 

SLS Materials

We supply our SLS prototypes in Nylon and Glass-Filled Nylon, giving you a choice of materials dependent upon your rapid prototyping requirements. Nylon and Glass-Filled Nylon provide good long term stability, strength and durability required for form, fit and functional testing.

SLS part with high level of finishing

3T currently offer the following materials for SLS:-

• Polyamide PA2200 (Nylon 12)
• Glass Filled Polyamide PA3200 (Nylon 12)

Find full SLS material specifications

Finishing & Colouring

Our Finishing & Colouring section explains how our skilled model makers ensure every last detail is taken care of, from the application of a single colour to a fully painted exhibition standard finish, and how our bespoke finishing services generate models that are comparable to the final manufactured item.

Our rapid manufacturing techniques now include a pioneering low cost method of improving the visual impact of our prototype components with a revolutionary colouring process. Requiring no surface dressing, functionality and lead time remain unaffected. An additional service we offer is fitting inserts into your prototype parts.

Direct Metal Laser Sintering (DMLS)

Having recently taken delivery of our third EOS M270 machine, we have one of the UK's largest DMLS capabilities.

Our newly commissioned DMLS facility has some of the latest rapid manufacturing technology and an expert team of engineers and finishers to generate metal parts that are comparable to a good investment cast part, with mechanical properties comparable to those of a cast or machined component.

Many companies are dramatically reducing their time to market and more and more are adopting the DMLS process for low volume production of their components, i.e. 'Rapid Manufacturing'.

Example of Rapid Manufacturing: Bed of aerospace parts in DMLS

DMLS is a fast, flexible and cost-effective manufacturing method giving you rapid prototype or production parts direct from your 3D CAD data, without the investment in time and money of conventional tooling. Complex geometries can be achieved such as holes, tunnels and voids, with the 'unsintered' or loose material simply being removed and recycled for future use, making it both economical and environmentally friendly.

DMLS Machines

We have three EOSINT M270 Metal Sintering Machines, each with an effective build volume of 250x250x215mm.

 

We use a DMC 835V Vertical Machining Centre providing us with the in-house ability to remove the supports from the DMLS components once they have been built, using accurate CNC machining methods.

Find full Machine Specifications

DMLS Materials

There are a number of different materials available for use with the EOS M270, varying from Bronze-based alloys to Tool Steels, Super-alloys and Composites. Some metal prototyping materials are more suited to certain applications than others, ie. parts for aerospace and automotive environments can be produced using Cobalt Chrome or 316L and 15-5PH Stainless Steels, with Inconel 718 and Titanium 6-4 (TiAl6V4) being ideal for many high temperature applications within these industry sectors. Tooling is generally made using Bronze or Maraging Steel.

DMLS part in Cobalt Chrome, shot-peened with metal and ceramics

3T currently offer the following metal prototype materials for DMLS:-

• Stainless Steel 15-5PH (EOS PH1)
• Cobalt Chrome alloy (EOS CC MP1)
• Dental Cobalt Chrome alloy (EOS CC SP2)
• Maraging Steel 1.2709 (EOS MS1)
• Direct Metal - Bronze (EOS DM20)

Find full DMLS material specifications

Prototype Finishing

Metal parts can be supplied 'as-built' or finished using various post processing and finishing techniques by our team of expert finishers.

Dependent upon the material used, there are various forms of finishing available; shot-peening, a cold working process used to produce a compressive residual stress layer and modify mechanical properties of metals; polishing or buffing, a process of smoothing metals and alloys and polishing to a bright, smooth, mirror-like finish. This can enhance the aesthetic appearance of parts as well as preventing corrosion.

Highly polished finish on aerospace prototype made in Cobalt Chrome