UNIT 4

Laser Based Additive Manufacturing

Processes
Classification of AM Processes
 Selective Laser Sintering (SLS)
• Selective laser
sintering (SLS) is
an additive
manufacturing (AM)
technique that uses
a laser as the power and
heat source
to sinter powdered
materials, aiming the
laser automatically at
points in space defined by
a 3D model, binding the
material together to [Link]
create a solid structure. [Link]

[Link]
50
 SLS Process Selective laser sintering process

1 Laser
2 Scanner system
3 Powder delivery system
4 Powder delivery piston
5 Roller
6 Fabrication piston
7 Fabrication powder bed
8 Object being fabricated (see
inset)
A Laser scanning direction
B Sintered powder particles
(brown state)
C Laser beam
D Laser sintering
E Pre-placed powder bed
(green state)
F Unsintered material in
previous layers
[Link]
 Sintering Mechanism
• Sintering in SLS primarily occurs in the
liquid state when the powder particles
forms a micro-melt layer at the
surface, resulting in a reduction in
viscosity and the formation of a Diagram showing formation of neck
concave radial bridge between in two sintered powder particles.
particles, known as necking, due to the Original shapes are shown in red.
material's response to lower its surface
energy.

[Link]
ntering
SLS Mechanism

[Link]
-by-hari-prasad
Introduction
SLS is a rapid prototyping (RP) process that builds models from
a wide variety of materials using an additive fabrication method.
The build media for SLS comes in powder form, which is fused
together by a powerful carbon dioxide laser to form the final
product.
SLS currently has 10 different build materials that can be used
within the same machine for a wide variety of applications.
The SLS® process is the only technology with the capability to
directly process a variety of engineering thermoplastic
materials, metallic materials, ceramic materials, and
thermoplastic composites.
[Link]
[Link]
[Link]
 (SLS) is an additive manufacturing technique that uses a high
power laser to fuse small particles of plastic, metal , ceramic,
or glass powders into a mass that has a desired 3-dimensional shape. The
laser selectively fuses powdered material by scanning cross-sections
generated from a 3-D digital description of the part on the surface of a
powder bed. After each cross-section is scanned, the powder bed is
lowered by one layer thickness, a new layer of material is applied on top,
and the process is repeated until the part is completed.
Step Steps in SLS
Powder Bed: Spread a thin layer of powdered material on a build platform.
1
This powder serves as the raw material.
Scanning the Laser: Use a high-power laser beam, precisely controlled by a
2 computer, to scan the cross-section of the 3D model onto the current layer of
powdered material. The laser fuses the powder at specific locations.
Solidification and Cooling: As the laser traces the pattern, the material fuses
3 together and solidifies. The heat dissipates, allowing the layer to cool and
harden.
Layer-by-Layer Build: Lower the build platform or raise the powder bed to
4 create space for the next layer of powder. Repeat the scanning and sintering
process for each layer.
Support Structures (if necessary): Create temporary support structures
5 alongside the main object for complex geometries. These provide stability
during printing.
Finishing: Remove the printed object from the loose powder. Clear excess
6 powder through brushing or blowing. Remove any support structures. Perform
post-processing steps like sanding, polishing, or heat treatment as needed.
Principle
The SLS® process is based on the following two principles:
(1) Parts are built by sintering when a CO2 laser beam hits a thin
layer of powdered material. The interaction of the laser beam with
the powder raises the temperature to the point of melting, resulting
in particle bonding, fusing the particles to themselves and the
previous layer to form a solid.
(2) The building of the part is done layer by layer. Each layer of the
building process contains the cross-sections of one or many parts.
The next layer is then built directly on top of the sintered layer after
an additional layer of powder is deposited via a roller mechanism on
top of the previously formed layer.
 Parameter Description
The intensity of the laser beam, which affects the level of energy applied to the
Laser Power
powdered material. Higher power results in stronger sintering.
The speed at which the laser beam moves across the powder bed. Faster speeds
Scan Speed
may reduce dwell time and heat exposure.
The vertical distance between each successive layer. Smaller layer thickness can
Layer Thickness
lead to finer details but longer build times.
The path taken by the laser to scan each layer, which can be continuous or
Scanning Strategy
hatching. Hatching is often used for better part density.
Powder Material Material characteristics, including particle size, flowability, and thermal
Properties conductivity, can impact the sintering process.
The temperature of the build chamber or the powder bed before and during
Preheating
printing, which can affect material flow and sintering.
The distance between laser paths during hatching, which influences the part's
Hatch Spacing
density and surface finish.
The method and speed used to evenly distribute a new layer of powder after each
Recoating Strategy
sintering pass.
The orientation of the 3D model within the build volume, which can affect print
Part Orientation
quality, support requirements, and warping.
How and when the printed part is cooled after each layer to minimize distortion
Cooling Strategy
and improve dimensional accuracy.
Design and generation of temporary support structures to stabilize overhanging or
Support Structures
complex geometries.
Additional steps such as heat treatment, surface finishing, and part removal from
Post-Processing
loose powder.
Materials
Polyamide.
Trade named “DuraFormTM”, this material is used to create rigid and
rugged plastic parts for functional engineering environments. This
material is durable, can be machined or even welded where required.
A variation of this material is the polyamide based composite system,
incorporating glass-filled powders, to produce even more rugged
engineering parts. This composite material improves the resistance to
heat and chemicals.
Thermoplastic elastomer.
Flexible, rubber-like parts can be prototyped using the SLS. Trade
named, “SOMOS® 201”, the material produces parts with high
elongation. Yet, it is able to resist abrasion and provides good part
stability. The material is impermeable to water and ideal for sports
shoe applications and engineering seals.
Polycarbonate.
An industry-standard engineering thermoplastic. These are suitable for creating
concept and functional models and prototypes, investment casting patterns for
metal prototypes and cast tooling, masters for duplication processes, and sand
casting patterns. These materials only require a 10–20 W laser to work and are
useful for visualizing parts and working prototypes that do not carry heavy
loads. These parts can be built quickly and are excellent for prototypes and
patterns with fine features.
Nylon.
This material is suitable for creating models and prototypes that can withstand
and perform in demanding environment. It is one of the most durable rapid
prototyping materials currently available in the industry, and it offers
substantial heat and chemical resistance. A variation of this is the Fine Nylon
and is used to create fine-featured parts for working prototypes. It is durable,
resistant to heat and chemicals, and is excellent when fine detail is required.
Metal.
This is a material where polymer coated stainless steel powder is
infiltrated with bronze. Trade named “LaserForm ST-100”,the material
is excellent for producing core inserts and preproduction tools for
injection molding prototype polymer parts. The material exhibits high
durability and thermal conductivity and can be used for relatively
large-scale production tools. An alternative material is the copper
polyamide metal–polymer composite system which can be applied to
tooling for injection molding small batch production of plastic parts.
Ceramics.
Trade named “SandFormTM Zr” and “SandformTM Si”,these use
zircon and silica coated with phenolic binder to produce complex sand
cores and molds for prototype sand castings of metal parts.
 Applications
(1) Concept models.
Physical representations of designs used to review design ideas, form and
style.
(2) Functional models and working prototypes.
Parts that can withstand limited functional testing, or fit and operate within
an assembly.
(3) Polycarbonate (RapidCastingTM) patterns.
Patterns produced using polycarbonate, then cast in the metal of choice
through the standard investment casting process. These build faster than wax
patterns and are ideally suited for designs with thin walls and fine features.
These patterns are also durable and heat resistant.
(4) Metal tools (RapidToolTM).
Direct rapid prototype of tools of molds for small or short production runs.
· Rapid Manufacturing
o Aerospace Hardware
o Medical and Healthcare
o Electronics; Packaging, Connectors
o Military Hardware
· Rapid Prototypes:
o Functional Proof of Concept Prototypes
o Design Evaluation Models (Form, Fit & Function)
o Product Performance & Testing
o Engineering Design Verification
o Wind-Tunnel Test Models
· Tooling and Patterns:
o Rapid Tooling (concept development & bridge tools)
o Injection Mold Inserts
o Tooling and Manufacturing Estimating Visual Aid
o Investment Casting Patterns
o Jigs and Fixtures
o Foundry Patterns - Sand Casting
Prototypes for Reebok golf shoe soles produced by SLS®
(Courtesy 3D Systems)
Reebok Uses SLS Process for Developing Sports Shoes
In the initial developmental stages of a new spikeless golf shoe sole
design, Reebok’s Golf Division, USA, needed a rapid, cost efficient
way to create flexible prototypes for their design tests. The company
was up against very tight deadlines. Traditional prototyping methods
(standard tooling and injection molding) would have taken 30 to 60
days and cost the company US$3500 to $4000 per prototype. The
company decided to use the SLS® system to build [Link] took
only seven hours and about US$250 worth of materials. The
prototype soles were affixed to a pair of golf shoes and worn by an
experienced golfer for two rounds of golf. The company was able to
save thousands of dollars and more than a month in development
time.
 Rapid Prototyping (through SLS) as Visualisation Aids for Architectural Use

Analysis of the Project:

The SLS growing time was approximately 94 hours, utilising some 6 kg of
Duraform, resulting in the following costs
3D CAD modeling ($ 650)
Prototyping ($ 2 260)
Finishing/presentation: ($ 870)
Total project cost ($ 3 780)
 Advantages
(1) Good part stability.
Parts are created in a precise controlled environment. The process
and materials provide for directly produced functional parts to be
built.
(2) Wide range of processing materials
. A wide range of materials including polyamide, glass-filled
polyamide composite, polystyrene, metals and foundry sands thus
providing flexibility and a wide scope of functional applications.
(3) Support structures not required.
not require support structures or uses only simplified support
structures . This increases the efficiency of the system by
reducing the processing time of the build.
(4) Little post-processing required.
The finishing of the part is very good thus requiring only minimal
post-processing.
(5) High accuracy.
the polystyrene it uses can be laser-sintered at a relatively low
temperature, thereby causing low shrinkage and high inherent
building accuracy.
(6) No post-curing required.
The completed part is by itself solid enough and does not require
post-curing.
(7) Large parts can be built.
The large build volume allows for relatively larger and taller parts
to be built. Large single parts can be built at one go rather than by
the building of smaller parts to be later joined together.
 Disadvantages
(1) Dedicated systems.
Only dedicated systems for plastic, metal and sand are
available respectively.
(2) High power consumption.
require relatively high laser power in order to directly sinter
the metal powders.
(3) Large physical size of the unit.
The system requires a relatively large space to house.
(4) Initial Cost of the System
The initial cost of the Sinterstation systems range from
$250,000 to $380,000, depending on the options and
peripherals acquired and excluding facility modifications.
(5) Maintenance and Operation Costs
Since the Sinterstations are large and complex systems, the
maintenance contracts currently run in the $35,000 annual range.
Also, the powders must be properly stored and recycled for further
use. The power consumption of the system and all its peripherals
can be high and must be taken into account, along with the smaller
costs of expendable inerting gases, build materials, and part
finishing supplies.
SLS (Selective Laser Sintering)
» Perfect for functional and robust parts, including living hinges and snap fits

» Ideal for 1 – 2 prototypes and up to 100+ parts

» Tool-less manufacturing

» Heat deflection up to 285°F

» Excellent for chemical resistance

» Quick-turn deliveries

» Less post-finishing requirements than SLA

» Paintable and platable

» Incredible Surface Quality

DMLS (Direct Metal Laser Sintering)

» Replaces the need for 4th and/or 5th Axis Machining

» Excellent tolerances

» Pure Alloys

» Reduces part delivery from weeks to days

» Parts can be post machined, welded and more

» Heat deflection up to 2000°C

» Equal to wrought in strength

» 99.99% dense

» Reduce part delivery from weeks to days

 DMLS (Direct Metal Laser
Parameter SLS (Selective Laser Sintering)
Sintering)
Metal powders (e.g., Inconel, Low temperature metals, Polymer
Material Type
titanium, steel) powders (e.g., nylon, PA12, TPU)
Laser Type High-power fiber laser CO₂ laser
Laser fuses metal powder Laser sinters polymer powder particles
Process Principle
particles layer by layer below melting point
Required for thermal stress Not required; unsintered powder acts
Support Requirement
management as support
Near 100% (fully dense metal 90–95% (slightly porous polymer
Part Density
parts) parts)
Surface Finish Rough; requires post-processing Relatively smoother
Dimensional Accuracy Very high Moderate to high
Good but lower than injection-molded
Mechanical Properties Comparable to wrought metals
plastics
Stress relief, support removal,
Post-Processing Depowdering and minor finishing
surface finishing
Aerospace, medical implants, Prototyping, consumer products,
Applications
tooling, heat exchangers automotive parts
High (expensive materials and
Production Cost Lower (cost-effective for polymers)
setup)
Slower (metals take longer to
Build Speed Faster (polymers fuse quickly)
process)
Functional polymer prototypes and
Typical Output Functional metal components
parts
 Parameter Fiber Laser CO₂ Laser
Optical fiber doped with
Laser Medium rare-earth elements (e.g., Gas mixture (CO₂, N₂, He)
ytterbium)
Wavelength ~1.06 µm (near-infrared) ~10.6 µm (far-infrared)
Best for metals (steel, Best for non-metals (wood,
Material Suitability
aluminum, copper, brass, etc.) plastic, glass, acrylic)
Energy Efficiency High (30–40%) Low (10–15%)
Beam Quality Excellent; fine, focused beam Moderate; larger beam spot size
Slower on metals; faster on
Cutting Speed Faster for thin metals
non-metals
Low (solid-state design, no High (requires alignment and gas
Maintenance
mirrors/gas refilling) replacement)
Operating Cost Low Higher
Lifespan Long (>100,000 hours) Shorter (~20,000 hours)
Cooling Requirement Less cooling needed Requires more cooling
Initial Cost Higher Lower
Metal cutting, engraving,
welding, additive Non-metal cutting, engraving,
Applications
manufacturing (e.g., DMLS, marking, prototyping (e.g., SLS)
WAAM)
 3D Printing (3DP)
•Three-dimensional printing, or 3DP, is an MIT-licensed
process, whereby liquid binder is jetted onto a powder
media using ink jets to "print" a physical part from
computer aided design (CAD) data.
•The initial powder used was starch based and the binder
was water based, however now the most commonly used
powder is a new gypsum based material with a new binder
system as well.
•Models are built up from bottom to top with layers of the
starch powder and binder printed in the shape of the cross
sections of the part.
•The resulting porous model is then infiltrated with wax or
another hardener to give the part dexterity.
Cond.
• The process is similar to the Selective Laser Sintering (SLS)
process, but instead of using a laser to sinter the material, an
ink-jet printing head deposits a liquid adhesive that binds the
material.

• Material options, which include metal or ceramic powders, are

somewhat limited but are inexpensive relative to other additive
processes.

• 3D Printing offers the advantage of fast build speeds, typically

2-4 layers per minute. However, the accuracy, surface finish,
and part strength are not quite as good as some other additive
processes.

• 3D Printing is typically used for the rapid prototyping of

conceptual models (limited functional testing is possible).
 Working Principle
1. Layer-by-Layer Process: The object is built in layers, with each layer
representing a cross-section of the part
2. Powder Bed Setup: A thin layer of powdered material (metal, ceramic, or
polymer) is spread over a build platform.
3. Binder Jetting: An inkjet-style printhead selectively deposits a liquid binder onto
the powder bed, bonding the particles in the desired areas.
4. Powder Layering: After each layer is bonded, the platform lowers, and a new
layer of powder is spread on top of the previous one.
5. Repetition: The binder deposition and powder layering steps are repeated until the
entire part is built.
6. Unbound Powder: The excess unbound powder remains in the bed and can be
reused for future builds.
7. Post-Processing: The printed object may undergo additional steps like sintering,
curing, or infiltration to improve its mechanical properties and achieve the final
material characteristics.
• The 3D printing process begins with the powder supply being
raised by a piston and a leveling roller distributing a thin layer
of powder to the top of the build chamber.
• A multi-channel ink-jet print head then deposits a liquid
adhesive to targeted regions of the powder bed.
• These regions of powder are bonded together by the
adhesive and form one layer of the part.
• The remaining free standing powder supports the part during
the build.
• After a layer is built, the build platform is lowered and a new
layer of powder added, leveled, and the printing repeated.
• After the part is completed, the loose supporting powder can
be brushed away and the part removed.
• 3D printed parts are typically infiltrated with a sealant to
improve strength and surface finish.
[Link]
 Postprocessing
1. Powder Removal. After the parts are taken from the machine,the
excess powder must be removed. With the system comes a small
glove box with an airbrush system [Link] airbrush is used to
easily and gently blow the powder off the part, and a vacuum
cleaner is hooked to the glove box to remove the powder as it is
blown from the part. (5 Minutes)

2. Heat for Infiltration. Once the powder is removed from the part
surfaces, the part is placed in a small oven and heated to a
temperature just above that of the infiltrant wax, to provide a
wicking characteristic as opposed to coating. The part
temperature for paraffin infiltrant is approximately 200°F.(10
Minutes)

3. Infiltration. Immediately after the part is heated, it is dipped for a

few seconds into a vat of molten wax, then removed and placed
on a sheet to dry. After drying the part is complete.(5 Minutes)
 Advantages
(1) High speed.
Fastest 3D printer to date. Each layer is printed in seconds, reducing
the prototyping time of a hand-held part to 1 to 2 hours.
(2) Versatile.
Parts are currently used for the automotive, packaging,education,
footwear, medical, aerospace and telecommunications industries.
Parts are used in every step of the design process for
communication, design review and limited functional testing. Parts
can be infiltrated if necessary, offering the opportunity to produce
parts with a variety of material properties to serve a range of
modeling requirements.
(3) Simple to operate.
The office compatible Zcorp system is straightforward to operate and
does not require a designated technician to build a part. The system is
based on the standard, off the shelf components developed for the
ink-jet printer industry,resulting in a reliable and dependable 3D
printer.
(4) No wastage of materials.
Powder that is not printed during the cycle can be reused.
(5) Color.
Enables complex color schemes in RP-ed parts from a full 24-bit
palette of colors.
 Disadvantages
(1) Limited functional parts.
Relative to the SLS, parts built are much weaker, thereby
limiting the functional testing capabilities.
(2) Limited materials.
The materials available are only starch and plaster-based
materials, with the added option to infiltrate wax using the ZW4
Waxer.
(3) Poor surface finish.
Parts built by 3D printing have a relatively poorer surface finish
and post-processing is frequently required.
Sports Shoe Industry
The 3D printer has been used by designers, marketers,
manufacturers,and managers in the footwear industry. Leading
athletic shoe companies, such as Adidas, have used this RP system
to radically reduce prototype development time and communicate
in new ways . Shoe industries these days are faced with constantly
changing consumer preferences and have to react quickly to stay
ahead of the business. With the 3D printer, lead times are
drastically reduced, beating the competition to the shelves with the
latest design trends whilst avoiding an excess inventory of
unwanted designs.
 Aspect Description
Full Form Three-Dimensional Printing (3DP)
Invented By Massachusetts Institute of Technology (MIT)
A liquid binder (adhesive) is selectively jetted onto a powder bed to bind the powder
Basic Principle
particles together layer by layer, forming a 3D part.
Process Type Binder Jetting (Additive Manufacturing Category)
1. A thin layer of powder (originally starch-based, now gypsum-based) is spread on the
build platform.
Working
2. Inkjet print heads selectively deposit a liquid binder according to CAD
Mechanism
cross-sections.
3. Layers are successively printed and bonded to form the full 3D object.
- Powder: Initially starch-based, now gypsum-based.
Materials Used
- Binder: Initially water-based, now proprietary chemical systems.
The printed part (porous and fragile) is infiltrated with wax, cyanoacrylate, or epoxy
Post-Processing
to strengthen and harden it.
Full-color, detailed models suitable for concept visualization, architectural models,
Output Nature
and prototypes — not for structural loads.
- Fast printing speed
Key Features - No need for support structures (unused powder supports the part)
- Can print in multiple colors using colored binders
- Concept models
- Architectural prototypes
Applications
- Medical visualization models
- Educational and design demonstrations
Laser Engineered Net Shaping
(LENS)
Laser Engineered Net
Shaping (LENS) is a 3D
printing technology that uses
a high-power laser to melt
and fuse powdered metals,
alloys, or composites to
create complex
three-dimensional structures
layer by layer.
 LASER ENGINEERED NET SHAPING (LENS)
Sandia National Laboratories has developed a new technology to fabricate
three-dimensional metallic components directly from CAD solid models.
Metal Additive Manufacturing: Primarily works with metals and metal alloys.
1.

Powder Delivery System: Fine metal powders are delivered and melted layer
2.

by layer.
High-Power Laser: Uses a laser (500W to 4kW) to melt metal powders
3.

precisely.
Direct Fabrication and Repair: Suitable for both new part fabrication and
4.

repairing worn/damaged parts.

High Material Utilization: Reusable powder, leading to minimal waste.
5.

Produce Large Parts: Can manufacture large, near-net shape parts.

6.

Precision& Complex Geometries: Enables the creation of intricate designs.

7.

Functionally Graded Materials: Multiple powder feeders allow for gradient

8.

materials.
Strong Material Properties: Produces parts with high structural integrity.
9.

Reduced Lead Times: Faster production compared to traditional

10.

manufacturing methods.
 Laser Engineered Net Shaping
(LENS)
• A laser beam [1] created by a laser
generator is focused through a lens
[2] onto the workpiece.
• Metal powder [3], or metal wire, is
introduced at the focus of the laser
beam, where the metal powder and
workpiece melt and thus building
on the surface.
• An inert gas [4] is supplied to
protect both the laser and the melt
from contamination during the
welding process.
[Link]
 LENS…

• The cross section of the

detail is thus built up
step by step until the
complete detail is
created.

• The method can also be

used to repair damaged
or worn surfaces and is
then often described as
laser welding with
powder.
Principle
The LENS process is based on the following two principles:

(1) A high powered Nd:YAG laser focused onto a metal

substrate creates a molten puddle on the substrate surface.
Powder is then injected into the molten puddle to increase
material volume.

(2) A “printing” motion system moves a platform horizontally

and laterally as the laser beam traces the cross-section of the
part being produced. After formation of a layer of the part, the
machine’s powder delivery nozzle moves upwards prior to building
next layer.

[Link]
•A high power laser is used to melt metal powder supplied coaxially
to the focus of the laser beam through a deposition head.

•The laser beam typically travels through the center of the head and
is focused to a small spot by one or more lenses. The X-Y tableThe
laser beam typically travels through the center of the head and is
focused to a small spot by one or more lenses. The X-Y table is
moved in raster fashion to fabricate each layer of the object. The
head is moved up vertically as each layer is completed.

•Metal powders are delivered and distributed around the

circumference of the head either by gravity, or by using a
pressurized carrier gas. An inert shroud gas is often used to shield
the melt pool from atmospheric oxygen for better control of
properties, and to promote layer to layer adhesion by providing
better surface wetting.
 The LENS process builds components in an additive manner from powdered
metals using a Nd:YAG laser to fuse powder to a solid. It is a freeform metal
fabrication process in which a fully dense metal component is formed. The LENS
process comprises of the following steps:

(1) A deposition head supplies metal powder to the focus of a high powered
Nd:YAG laser beam to be melted. This laser is typically directed by fiber optics
or precision angled mirrors.

(2) The laser is focused on a particular spot by a series of lenses, and a motion
system underneath the platform moves horizontally and laterally as the laser
beam traces the cross- section of the part being produced. The fabrication process
takes place in a low-pressure argon chamber for oxygen-free operation in
the melting zone, ensuring that good adhesion is accomplished.
(3) When a layer is completed, the deposition head moves up and continues with
the next layer. The process is repeated layer by layer until the part is completed.
The entire process is usually enclosed to isolate the process from the
atmosphere. Generally the prototypes need additional finishing, but are fully
dense products with good grain formation.
Capabilities

• Ability to build fully dense shapes.

• Closed loop control of process for accurate part fabrication.

• Composite and functionally graded material deposition.

• Three- and four-axis systems for complex part fabrication.

• Wide variety of materials that, at minimum, include: stainless

steel alloys (316, 304L, 309, 17-4), nickel-based superalloys (Inco
designations 625, 600, 718, 690), tool steel alloys (H13), titanium
alloy (6Al- 4V), and other specialty materials.

• Mechanical properties similar or better than traditional

processing methods.
 Process flow

1. Preparation of CAD Model

2. Material Selection
3. Setup of LENS Machine
4. Layer-by-Layer Deposition
5. Melting and Solidification
6. Cooling and Solidification
7. Post-Processing
 Steps in LENS
• 1. Preparation of CAD Model:
• The process begins with the creation of a detailed 3D CAD model of the desired object or
component that needs to be manufactured.
• 2. Material Selection:
• A suitable metal powder is chosen based on the requirements of the final product. Common
materials include stainless steel, titanium, aluminum, and various alloys.
• 3. Setup of LENS Machine:
• The LENS system consists of several components including a high-power laser, a focusing
lens, a nozzle for powder delivery, and a computer-controlled 3D motion system.
• The metal powder is loaded into a hopper which is then directed through a nozzle onto the
build surface.
• 4. Layer-by-Layer Deposition:
• The LENS process operates layer by layer. The metal powder is directed onto the substrate
or the previously deposited layer.
• Simultaneously, a high-power laser beam is precisely focused on the area where the powder
is being deposited. The laser melts the metal powder, fusing it with the existing material.
• The computer-controlled motion system ensures the accurate positioning of the laser and
the substrate, following the design specifications layer by layer.
• 5. Melting and Solidification:
• The laser melts the metal powder upon contact, creating a small molten pool.
• As the laser moves, the molten pool solidifies, forming a solid metal layer. This process is
repeated layer by layer, with each new layer fusing with the previous one as it cools down.
 Cont.,
• 6. Cooling and Solidification:
• Adequate cooling is crucial to maintain the structural integrity of the part.
• Some LENS machines have a controlled atmosphere or a substrate heating
system to optimize the cooling process and prevent warping and cracking.
• 7. Post-Processing:
• Once the printing is complete, the manufactured part may require additional
post-processing steps such as machining, polishing, or heat treatment to achieve
the desired surface finish and mechanical properties.
Advantages of LENS Technology:
• Customization: LENS allows for the production of highly customized and complex
parts that are difficult or impossible to manufacture using traditional methods.
• Material Efficiency: LENS minimizes material wastage since it only uses the
necessary amount of metal powder required for the specific part being
manufactured.
• Rapid Prototyping and Repair: LENS is valuable for rapid prototyping and
repairing existing components, saving time and costs associated with traditional
manufacturing methods.
• It's important to note that LENS technology continues to evolve, with ongoing
research aimed at improving precision, speed, and the range of materials that can
be used.
 Advantages

(1)Superior material properties.

The LENS process is capable of producing fully dense metal
parts. Metal parts produced can also include embedded structures
and superior material [Link] microstructure produced is
also relatively good.

(2) Complex parts.

Functional metal parts with complex features are the forte of
the LENS system.

(3) Reduced post-processing requirements.

Post-processing is minimized, thus reducing cycle time.
 Disadvantages
(1)Limited materials.
The process is currently narrowly focused to produce only metal
parts.

(2) Large physical unit size.

The unit requires a relatively large area to house.

(3) High power consumption.

The laser system requires very high wattage.

(4)The current disadvantage is a rough surface finish and low

dimensional accuracy acquired in LENS parts. Typically LENS
parts must be polished or finish machined to fit required tolerances.
 Applications

The LENS technology can be used in the following areas:

(1)Build mold and die inserts

(2) Producing titanium parts in racing industry

(3) Fabricate titanium components for biological implants

(4) Produce functionally gradient structures

(5)This technique can be used with a wide variety of metals

including titanium, tool steels, stainless steels, copper and
aluminum.
H13
Tooling

WES Housing
Impeller

Fixtures