Additive manufacturing at 3D laser BW

Industrial additive manufacturing (AM), also known as 3D laser printing, is an innovative manufacturing process that differs fundamentally from conventional manufacturing processes and opens up new possibilities for the industry to manufacture components.

The components are built up in additive layers directly from digital 3D CAD data, without the need for conventional tools or molds.

A key process at 3D Laser BW is laser powder bed fusion (LPBF), also known as selective laser melting (SLM). This involves applying fine metal powder in thin layers to a build platform and melting it locally with a laser beam with pinpoint accuracy. Layer by layer, a precise, resilient metal component is created, designed exactly according to its geometry and function.

The biggest advantage of additive manufacturing — i.e., metal 3D printing — is that it eliminates the need to develop and manufacture tools and molds for the production of a component. Instead, as in selective laser melting, components are produced layer by layer based on 3D CAD files. This manufacturing process enables companies to produce components more cheaply and quickly and to offer custom-made products more easily.

Another advantage is that additive manufacturing allows for greater freedom in terms of complex geometries and functional integrations that cannot be achieved with conventional manufacturing processes.

3D Laser BW manufactures metal direct components with complex geometries and hollow or lattice structures. In addition to additive manufacturing, the portfolio covers the entire component design and manufacturing process – from consulting, design, simulation, and feasibility testing to mechanical post-processing (using our own 5-axis CNC machining), surface treatment, and assembly of components. On request, the specialists at 3D Laser BW can also develop custom-fit metal powders.

3D Laser BW offers the most common process for industrial additive manufacturing of metal components — selective laser melting (powder bed-based melting of metal using a laser beam).

In the field of additive manufacturing, 3D Laser BW from Kirchheim unter Teck focuses specifically on selective laser melting (SLM) when it comes to complex, high-strength metal components. In SLM, metal powder is completely melted layer by layer using a laser beam and thus built up into a dense, resilient component – directly from the CAD data, without molds or tools.

Thanks to many years of expertise and state-of-the-art machinery, the specialists at 3D Laser BW produce functionally optimized one-off pieces as well as components suitable for series production from materials such as stainless steel, aluminum, or titanium – precisely, quickly, and economically.

Selective laser melting allows the component to be customized. The process is:

• powder bed-based (laser powder bed fusion - LPBF)
• suitable for manufacturing filigree components
• produces cooling channels from 0.5 mm in diameter
• is ideal for manufacturing smaller, functionally integrated components

The specialists at 3D Laser BW currently process the following materials:

• 1.4404
• 1.4542
• Inconel 625
• Inconel 718
• AlSi10Mg
• 1.2709

Selective laser melting (SLM), also known as laser powder bed fusion (LPBF), is a high-precision additive metal manufacturing process that is used specifically for demanding applications at 3D Laser BW. The complete melting of the metal powder results in virtually pore-free components with a homogeneous microstructure and high strength, ideal for resilient, durable components.

Thanks to the layer-by-layer build-up from 3D CAD data, complex geometries can be created without tooling costs, free of mold parting lines and with high reproducibility. Even filigree structures, internal cooling channels or lattice geometries can be realized with precision.

SLM is compatible with a wide variety of materials. 3D Laser BW processes aluminum, stainless steel, and titanium alloys, as well as high-temperature materials such as Inconel and special steels. The selection is always application-specific and takes into account the subsequent mechanical, thermal, or chemical stresses.

Compared to conventional manufacturing methods, selective laser melting (SLM) offers numerous advantages that 3D Laser BW makes available to its customers in a targeted manner. The process opens up new possibilities – both technologically and economically.

Tool-free manufacturing
SLM does not require molds or casting tools. This makes the process ideal for prototypes, small series made of metal, and individual custom-made products.

Cost efficiency and time savings
Direct conversion from CAD data reduces development cycles to a minimum.

High design freedom
SLM enables the implementation of highly complex, functionally integrated geometries.

Process reliability
SLM offers reproducibility through automatic layer construction

Functionally optimized components for specific applications
SLM is ideal for manufacturing functionally optimized components, for example, close-contour cooling channels in tool and mold making.

Learn more about the selective laser melting process below.

Once the design data has been received, a detailed feasibility study is carried out. Based on this, 3D Laser BW provides the customer with individual advice and identifies the optimal approach for additive manufacturing using selective laser melting (SLM). The component is then specifically adapted for the SLM process and optimized in terms of design.

In selective laser melting (SLM), metal in powder form is processed layer by layer. The powder is first applied evenly to a build platform and then melted at defined points by a precisely controlled fiber laser. The material melts locally to form a solid, dense component.
Once a layer has been completely built up, the build platform lowers slightly, a new layer of powder is applied, and the process begins again.

Once the construction process is complete, the excess metal powder is carefully removed. The finished component is then separated from the build plate and the necessary support structures are removed.

In the next step, the component can be specifically post-processed according to requirements. This includes heat treatments to reduce residual stresses, CNC machining to achieve tight tolerances, and polishing or grinding for improved surface quality. Additional surface finishes such as coating, electropolishing, or anodizing are available on request. The result is a functional, ready-to-install precision component made from the raw part printed in the SLM process, individually tailored to your application.

Metallic 3D printing with SLM (selective laser melting), also known as LPBF (laser powder bed fusion), offers new possibilities for design and manufacturing across a wide range of industries. From rapid prototyping to functionally integrated series components, this additive manufacturing technology enables complex geometries, maximum precision, and cost-effective solutions. Below you will find the most important areas of application for 3D Laser BW.

3D Laser BW is your partner for additive manufacturing in the automotive industry. We manufacture prototypes, pre-series parts, and small series from metal by combining LPBF (Laser Powder Bed Fusion / SLM) and state-of-the-art 5-axis milling technology. We produce motorsport and special vehicle parts as well as tool inserts with close-contour cooling precisely, economically, and in the highest quality.

In aerospace technology, 3D Laser BW supplies high-precision, weight-optimized structural and functional components. Additive manufacturing (SLM) and subsequent 5-axis machining are used to create lightweight structures for satellites and space systems. Our documented quality assurance guarantees components for the most extreme requirements, ready for assembly and reliable.

3D Laser BW manufactures robust, durable components for land, air, and marine systems for the defense industry. In particular, the combination of 3D metal printing (SLM) and 5-axis milling ensures maximum dimensional accuracy, resilience, and traceability.

In mechanical engineering, 3D Laser BW produces individual parts, functional models, and assembly components, as well as guides, spindle components, and fixtures. Additive manufacturing with LPBF (SLM) enables these complex geometries.

3D Laser BW manufactures implants and surgical instruments from stainless steel for medical technology. The LPBF (SLM) process allows the production of highly complex geometries, which are precisely finished using 5-axis milling. The result: biocompatible, safe, and precisely fitting medical devices.

In tool and mold making, 3D Laser BW combines additive manufacturing with LPBF (SLM) for contour-close cooling with precise 5-axis milling. This results in high-quality, durable tools and inserts that enable shorter cycle times and increased productivity.

For the energy sector and power plant technology, 3D Laser BW manufactures turbine, pump, and compressor parts from high-strength materials. SLM technology is used to create functionally optimized structures.

In the oil, gas, and chemical industries, 3D Laser BW supplies corrosion-resistant metal components for valves, pumps, and offshore systems. Additive manufacturing (SLM) enables a wide range of complex geometries.

For the electronics and electrical engineering industry, 3D Laser BW produces housings, heat sinks, and interface components. Additive manufacturing with SLM ensures lightweight and robust structures.

3D Laser BW manufactures brackets and safety-related components for railway technology, robust, durable, and dimensionally stable.

Whether bicycles, sports equipment, or design objects, 3D Laser BW supplies customized high-end components. Additive manufacturing (SLM) is used to create innovative lightweight structures for your components.

In semiconductor and vacuum technology, 3D Laser BW manufactures adapters, mounts, and system components with precision and purity.

For the food and packaging industry, 3D Laser BW manufactures stainless steel components, tools, and molds for hygienic applications. SLM technology creates efficient cooling structures that perfectly complement our 5-axis milling capabilities to ensure smooth and easy-to-clean surfaces.