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About Project

Dive into the world of advanced manufacturing with this intricate 3D-printed component made of pure copper. Created using Selective Laser Melting (SLM), this piece exemplifies the potential of metal additive manufacturing to produce complex geometries and functional designs.

At the heart of this component lies a gyroid structure, a triply periodic minimal surface renowned for its exceptional surface area to volume ratio. This intricate internal lattice is ideal for applications requiring efficient heat transfer, filtration, or fluid management.

Surrounding the gyroid core, the design incorporates a sophisticated system of perforated surfaces. One section features a honeycomb pattern of 0.5mm diameter holes, while adjacent sections utilize smaller, 0.2mm diameter holes. These varying hole sizes suggest a carefully engineered approach to flow control, filtration, or selective permeability.

It's important to note the fine details and challenges of this print. While the design calls for precise 0.2mm holes, achieving perfect dimensional accuracy at this scale with SLM can be demanding. In this example, some of the smaller perforations exhibit slight imperfections, highlighting the critical interplay between design intent and manufacturing capabilities. These imperfections, however, can also be a key design feature, influencing flow restriction and diffusion characteristics.

This component showcases the power of SLM for creating highly specialized parts with complex internal geometries that would be impossible to produce using traditional manufacturing methods. Potential applications range from advanced heat exchangers and microfluidic devices to filtration systems and lightweight structural components.

Ready to bring your complex metal designs to life?

FacFox offers cutting-edge pure copper 3D printing services using SLM technology. We specialize in producing high-quality metal parts with intricate details and complex geometries. Whether you need functional prototypes or end-use components, FacFox has the expertise and capabilities to deliver exceptional results.

Learn more about our pure copper 3D printing services and get a quote today!

Solution

• Step 1: A 3D model of the component was designed using CAD software.
• Step 2: The 3D model was sliced into thin cross-sectional layers.
• Step 3: Pure copper powder was loaded into the powder bed of the SLM machine.
• Step 4: A thin layer of powder was spread evenly across the build platform by a recoater blade or roller.
• Step 5: A high-energy laser beam was directed at the powder bed, selectively melting and fusing the copper particles according to the first cross-sectional layer of the design.
• Step 6: The build platform was lowered by a distance equal to the layer thickness.
• Step 7: Another layer of fresh powder was spread over the previously melted layer.
• Step 8: The laser beam was redirected to melt and fuse the new layer to the previous one, repeating the process for each cross-sectional layer.
• Step 9: These steps were repeated until the entire component was built.
• Step 10: After the build was complete, the component was left to cool within the powder bed.
• Step 11: The excess powder surrounding the component was carefully removed, typically using brushes, air jets, or vacuum systems.
• Step 12: The component was detached from the build platform, often by wire EDM (Electrical Discharge Machining), cutting, or other suitable methods.
• Step 13: Support structures, if used, were removed. These supports are often necessary to provide stability during the build process and prevent warping.
• Step 14: The component was subjected to stress relief heat treatment, if needed, to reduce residual stresses induced during the SLM process. This helps improve the mechanical properties and dimensional stability of the part.