Developing a cheaper, capable Direct Metal Laser Sintering 3D printer

This independent research project focuses on the development of a small-form Direct Metal Laser Sintering (DMLS) 3D printer capable of producing high-quality metal parts. The research involved consulting with professionals from DMG MORI and Scientists and conducting on in-depth study of loser Systems, motion systems, and powder-based additive manufacturing. Over the course of the project, various aspects of DMLS technology were explored, including optimizing laser parameters for precise sintering. designing compact motion control systems, and ensuring material compatibility for industrial- grade part production. The project also examined existing metal 3D printing solutions and identified key challenges related to cost, size, and accessibility. Through this research, a preliminary design framework was established for a compact and efficient DMLS system for small-scale applications. The most significant outcome of this project was the development of a technical roadmap for prototyping a small-form DMLS printer, which could contribute to broader advancements in affordable metal additive manufacturing.