Engineers have been producing metal components, not just prototypes, for several years using Optomec’s version of selective laser sintering (SLS), which the company calls LENS (Laser Engineered Net Shaping).
The components built have been relatively large, with a process work envelope of 900 mm x 1,500 mm x 900 mm (35.43 inch x 59.0 inch x 35.43 inch) for the company’s largest machine, the 850-R. That one deposits material such as standard steels, titanium, and nickel alloys at up to 500 g/hr (1.1 lb/hr).
Optomec says that for many applications the mechanical properties of components built with the process are equivalent to those of wrought metals. For example, independent testing has shown that the fatigue strength of Ti 6-4 matches the fatigue strength of wrought annealed material. Yield strength and tensile strength of the 3D-printed material were actually better at 973 MPa and 1077 MPa versus 834 MPa and 973 MPa, respectively, for Ti-6Al-4V, a titanium/aluminum alloy. Among other things, Ti-6Al-4V alloys are used for structural components on commercial aircraft.