Embedded Files
UC San Diego Makerspace
Our purpose was to create a reliable and consistent FDM metal printing process for the UCSD Makerspace.
Background
Traditional metal 3D printing techniques are inaccessible. Selected laser sintering (SLS) and direct metal laser sintering (DMLS) can easily cost over $500,000.
Fused Deposition Modeling (FDM) 3D metal printing is much less expensive, but is a relatively new field with little supporting documentation.
How does FDM metal printing work?
Step 1: Printing
Entry-level fused deposition modeling (FDM) polymer 3D printers, such as the Prusa i3, are modified to print PLA filament infused with metal powder. These printed parts are referred to as "green" parts.
Step 2: Debinding
The next step is debinding. In this step the PLA is burnt out of the green part by running it through a furnace for several hours. This produces what is referred to as a "brown" part.
Step 3: Sintering
The brown part is then placed in the furnace again for a process called sintering. In this step the heating of the part allows the metal particles to fill in the gaps left by the removal of the PLA.
Step 4: Post-Processing
These sintered parts can then be sand blasted or sanded to give them a more finished look. Additionally, bolt holes and similar features can be machined as in a bulk metal part for better tolerances.
Our Project
First we manipulated printer settings to improve print quality. Then we varied print, debinding, and sintering parameters that we believed would improve the quality of our debinding and sintering steps, focusing mainly on infill density and compression. Finally, we used material characterization techniques to get feedback on the effects of each parameter we varied.
Overall Success
Improvement in bronze benchies
Early bronze cube
Recent bronze cube
Early steel cube
Recent steel cube
Page updated
Report abuse