The future of 3D printing: How additive manufacturing is transforming production
3D printing opens up new possibilities for designing complex component geometries. Metal 3D printing processes have evolved from niche technologies to become an integral part of modern manufacturing. As a forward-looking addition to traditional machining technologies, these processes are becoming increasingly relevant — a key development in the context of Industry 4.0. Companies such as DMG MORI recognise the potential of 3D printing technologies for future production.
There are differences between subtractive and additive manufacturing (3D printing): In subtractive manufacturing, material is removed — for instance, through milling, turning or grinding — to create a component with the desired geometry. Additive manufacturing, on the other hand, follows a completely different principle. Using a professional metal 3D printer, the component is created layer by layer directly from the digital 3D model data. This basic principle remains the technological foundation of all modern 3D printing processes. The transition to 3D printing represents a significant milestone in industrial production, paving the way for more flexible, efficient, and customizable manufacturing processes.
Metal 3D printing processes as key technologies
Laser deposition welding (DED) is an additive process with a high build-up rate
Laser deposition welding is an early and still highly relevant process in the field of additive manufacturing. It belongs to the Directed Energy Deposition (DED) process group. Metal powder is introduced into a laser beam via a coaxial powder nozzle, which melts the powder with pinpoint accuracy. This process is notable for its particularly high build-up rate, enabling the layer-by-layer construction of complex components. Unlike powder bed processes, support geometries are not required for laser deposition welding because the 5-axis kinematics of the CNC milling machine always position the component optimally for the laser nozzle.
Thanks to twin powder feeders, two different metals can be applied alternately to give the component the desired properties, such as higher thermal conductivity or different degrees of hardness in certain areas. Graded materials with a smooth transition from one material to another can also be produced in this way.
Selective laser melting (SLM) is a high-precision powder bed process
Another forward-looking process is selective laser melting. In this process, metal powder is applied in thin layers to a build platform and then melted locally by a laser according to the component geometry. The area to be exposed is calculated in advance from the 3D model of the workpiece. Unused powder can be reused, making the process interesting from a resource efficiency perspective. Due to its wide range of applications, countless material powders are already available for generative component construction, including steels, aluminium alloys, cobalt chrome, nickel alloys, copper and titanium. This enables functional prototypes to be produced as series workpieces.
DED versus SLM: additive processes with different strengths
The main differences between directed energy deposition (DED) and selective laser melting (SLM) are the tolerances that can be achieved, the build-up rates and the production speeds. Although the powder bed process delivers higher precision, laser deposition welding is easier to integrate into hybrid machine tools. This enables additive and subtractive processes to be combined in a single setup, which is a decisive advantage in terms of productivity. However, both processes have their merits in different industries.
Diverse industry applications: from aerospace to medical technology
The design freedom offered by 3D printing is particularly advantageous where maximum precision in a minimum of space is required, as in the aerospace and medical technology sectors. DED machines have long been established in mould making and the aerospace industry. Laser deposition welding enables the fast and economical repair and maintenance of damaged components. In turn, medical technology uses the powder bed process to manufacture customised implants, such as dental or joint prostheses, that are precisely tailored to the patient.
The secrets to the success of additive manufacturing
Compared to conventional processes, additive manufacturing offers a whole new way of designing and producing things. It has great potential in terms of spare parts availability, internal geometries, complex component structures and small batch sizes. Another application area for 3D printing, both today and in the future, is in scenarios that lead to significantly improved product properties. Topology optimization, for instance, can greatly enhance a component's properties. Additively manufactured (bionic) structures can reduce weight while maintaining stability. Additive manufacturing processes offer particular advantages when components must meet high or very specific requirements. A continuous process chain combining »metallic 3D printing« with targeted post-processing is often more economical than conventional processes.
Additive manufacturing means additive thinking
To fully exploit its potential for components, additive manufacturing requires a rethink right from the product development stage. The challenge lies in the practical application of the technology and identifying its potential within a specific spectrum. This requires a thorough grasp of the various additive processes and their capabilities, as well as an open-minded approach. Ideally, companies should use sound analysis and consulting services to identify and exploit the added value of additive manufacturing. This enables the assessment of which components can be optimized in terms of function, weight, material usage or production costs through 3D printing.
Despite its innovative nature, 3D printing will not replace traditional processing technologies; rather, it will complement them in areas where its strengths are evident. It offers unique advantages, particularly for complex geometries, small batch sizes or integrating new functions. The further development of generative manufacturing in a wide range of industries and its integration into new business models is being looked at. It is clear that enormous potential for the future is held by 3D printing, provided it is used in a structured and forward-looking manner.
From powder to precision components
Since 2013, DMG MORI has supported its customers with integrated additive manufacturing processes. The company began with laser cladding using the LASERTEC DED and LASERTEC DED hybrid series. With the LASERTEC SLM series, the machine tool manufacturer's product range now also encompasses powder bed processes. As the global market leader in machine tool manufacturing, DMG MORI combines additive processes with a comprehensive range of high-performance machining solutions to offer unparalleled technological integration. The CELOS software platform ensures consistent, user-friendly operation, regardless of the technology used.
Expertise directly from the global market leader: DMG MORI's Excellence Centers
DMG MORI provides training to its customers in its own Technology Centers even before additive process chains are implemented. There, interested parties and users can gain in-depth knowledge of »metallic 3D printing«, conventional machining and how to integrate the two processes, with the ultimate goal of enabling optimal manufacturing solutions for more economical processes and higher-quality products.
Four additive process chains for industrial 3D printing
Based on its extensive portfolio in additive manufacturing and CNC technology, DMG MORI offers four additive process chains to meet a range of requirements:
- Powder bed plus machining: Workpieces are built up on LASERTEC SLM machines and then machined to produce additively manufactured components with maximum precision.
- Machining plus powder bed: The base body of milling heads, for example, is manufactured using conventional methods. This is followed by the complex assembly of the tool, including internal cooling channels.
- Powder nozzle plus finish machining: The LASERTEC 65 DED can manufacture sophisticated components for multi-material applications with a maximum size of 650 x 560 mm without the need for support contours. During finishing on a universal machining centre, flat surfaces and threads are finished to the required accuracy.
- DED hybrid machines: These enable switching between additive manufacturing using a powder nozzle and 5-axis simultaneous machining or 6-sided complete machining for even more complex workpieces and components up to Ø 1,010 x 3,702 mm.
DMG MORI is actively shaping the future of 3D printing
By combining additive manufacturing, hybrid machining and intelligent process control, DMG MORI is creating technologically and economically forward-looking solutions. Thanks to its technological expertise and intelligent process integration solutions, the company is playing a decisive role in the future of industrial 3D printing.