Monday, January 25, 2010

DMLS - Direct Metal Laser Sintering Costs and Materials

Happy Monday!

I just logged into analytic's and seen what people are searching when coming to this blog, the top searches include;

-Direct Metal Costs
-DMLS Materials
-Direct Metal Laser Sintering
-Tim Ruffner (yeah I'm so not making that up lol)
-EOS M270
-GPI Prototype

Instead of talking about myself or GPI Prototype I have decided to share with you some costs and materials using direct metal laser sintertering aka DMLS (dmls).

I'm going to post a picture of a part, although I can not share the STL file I will share the picture and go over what costs would be in each material. Costs include setting the job up, material, labor, running time, removal of supports and finishing (includes stress relieving and shot peening).



Part Size - 1 1/2" Tall 1 1/4" Wide 1" Long 20 micron layers

How the part is positioned on the plate and Z Axis is what really determines price. Z axis is very important because that basically is how much powder is being used. Everytime the build plate and vat go down the re-coater arm will re-coat the build plate with powder, essentially using that powder and time. The laser sintering of each layer is quite fast the plate moving for each layer either 20 or 40 microns and the re-coater arm moving from side to side pushing powder is what takes the most amount of time. Setting up the machine takes roughly an hour and a half. Setting up the file takes about 45 min. The part I am giving you a price on was supported width wise so only 1" in height, plus 1/4" in support (giving you clearance for a band saw blade to cut supports from the build platform). Total build time was about 6 hours. Total finishing (support removal and polishing prior to blasting) including post hardening (4 hour process) was about 7 hours. Total time in this one part was about 15 hours.

PH1 - $650.00.

That comes to about $43.00 an hr. Not too bad is it? Not at all considering you have a metal part that can only be made this one way (this part shown has conformal cooling channels). Now as you may or may not know this was only 1 of 4 total parts for this insert for a golf ball but done solely as demonstration purposes to show conformal cooling and to educate you on price.

Pricing is different for most parts, obviously there is quite a bit that has to go into consideration before we give out pricing. Put some of that info perspective and the service we offer and that price is far less expensive then conventional methods including time and service given to you from GPI.

Why am I so candid about pricing? Well because I am not scared lol just playing really because I want to educate you in this field, a lot are surprised by how inexpensive this method is. We are offering you a service not just in regards to your product but giving you complete satisfaction for your part and how you are treated. Quality is exceptional, delivery is phenomenal and service is second to none! Give GPI a chance, send us your file and see how GPI can take your concept to reality. You can send your files to timr@gpiprototype.com there is no obligation when it comes to quoting (although even quotes take up some time as we do a simulated run and see how much time is involved with finishing). Tool inserts are a great way to save costs using DMLS technology!

Have linkedin? Add me timr@gpiprototype.com

Tim Ruffner
Account Executive
GPI Prototype & Manufacturing Services, Inc.
940 North Shore Drive
Lake Bluff, IL 60044
http://gpiprototype.com
Phone: 847.615.8900
Fax: 847.615.8920
Email: Timr@GPIprototype.com
GPI Prototype DMLS on Twitter
Tim Ruffner LinkedIn
GPI Prototype on YouTube

73 comments:

  1. I know I hear quite often about the costs involved with DMLS. What type of time frame do you allow for finishing and also for quoting.?

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  6. Hi,
    can parts be nested within one another - say bowl shapes? Also if the these bowls have lids can the lids also be sintered at the same time if they are positioned so they are not touching? and does this arrangement impact on pricing?

    Object designer Australia

    ReplyDelete
  7. The blog started out saying
    "go over what costs would be in each material."

    We got PH1, what about the others???

    Very cool that you are talking about price, in any case.

    ReplyDelete
  8. Hi Anonymous....

    Yes you can build fully functional parts using the DMLS method. You can also do this in SLS as well for functional plastic parts. Bowls are no issue...

    Hi Paul,

    I will get on the other materials and email you when complete. I am working on something with http://custompartnet.com to show pictures and files for each different materials.

    Thanks for viewing!

    ReplyDelete
  9. Tim, my question was regarding nesting one bowl within a larger bowls z axis - producing 2 bowls from one cad model

    And how does this effect costing my assumption is that it would be considerably cheaper for the 2 bowls ?

    Object designer Australia

    ReplyDelete
  10. Mr Designer in Australia,

    You are correct, this would significantly reduce the costs and the parts can be welded with great results. Best results for welding would be Laser Welding. Reducing Z height will reduce your costs by quite a bit!

    You can always email me a file and I can help you with the design to reduce costs where I can!

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  53. Which machine are you doing this on? I just got a price on Renishaw's latest offering (AM125) and if you're charging only $43 an hour for parts out of a $430,000 machine I think I'll continue to make parts the old fashion way for awhile until the price of this technology comes way down.

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    1. Pardon me, $680,000 for the EOSint 280.

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  59. The laser interspersing of each layer is quite fast the plate moving for each layer either 20 or 40 microns and the re-cotter arm moving from side to side pushing powder is what takes the most amount of time.

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  63. n each material. Costs include setting the job up, material, labor, runnin

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