High Power Selective Laser Melting (HP SLM) of Aluminum Parts

TLDR

Selective Laser Melting produces lightweight, structurally complex parts with uniform mechanical properties without tooling or sintering, and aluminum is attractive for such components, yet current SLM technology and cost remain inadequate for large‑scale production. The study aims to enhance production efficiency by substantially increasing the build rate. To achieve this, the authors employ a prototype machine equipped with a 1 kW laser and a multi‑beam system, enabling high‑rate aluminum processing.

Abstract

Selective Laser Melting (SLM) is one of the Additive Manufacturing (AM) technologies that enables the production of light weight structured components with series identical mechanical properties without the need for part specific tooling or downstream sintering processes, etc. Especially aluminum is suited for such eco-designed components due to its low weight and superior mechanical and chemical properties. However, SLM's state-of-the-art process and cost efficiency is not yet suited for series-production. In order to improve this efficiency it is indispensable to increase the build rate significantly. Thus, aluminum is qualified for high build rate applications using a new prototype machine tool including a 1 kW laser and a multi-beam system.