Direct Metal Laser Sintering (DMLS) is a rapid prototyping technique that allows for direct and rapid manufacturing of complex components. DMLS is however an intricate process and the quality of the final product is influenced by multiple manufacturing parameters (or DMLS settings) and powder characteristics. The effect which each of these manufacturing parameters and powder characteristics has on the final parts is not well understood and the success of process manufacturing mainly relies on empirical knowledge. Consequently high dimensional deformation and relatively poor mechanical properties are still experienced in many DMLS products, in particular in copper-based laser sintered parts. A need therefore exists to systematically examine the effect of process parameters on the quality of final parts in order to determine the most appropriate manufacturing parameters for specific applications of copper-based laser sintered parts. This document summarises the effect of different process parameters on the quality of Direct Metal 20 laser sintered parts produced with a EOSINT M250 Xtended laser sintering machine from powder consisting of Ni5Cu, Cu15Sn – Cu5Sn and Cu8P – Cu2P material grains. The quality of the sintered parts is defined in terms of the microstructures, porosities and dimensional deformations obtained. The effects of three different geometric sintering strategies currently in standard use namely Solid Skin, Skin Stripes and Skin Chess were examined, and the more appropriate process parameters and scanning technique for the available set-up is presented. / MIng (Mechanical Engineering), North-West University, Potchefstroom Campus, 2015

Direct Metal Laser Sintering (DMLS) is a rapid prototyping technique that allows for direct and rapid manufacturing of complex components. DMLS is however an intricate process and the quality of the final product is influenced by multiple manufacturing parameters (or DMLS settings) and powder characteristics. The effect which each of these manufacturing parameters and powder characteristics has on the final parts is not well understood and the success of process manufacturing mainly relies on empirical knowledge. Consequently high dimensional deformation and relatively poor mechanical properties are still experienced in many DMLS products, in particular in copper-based laser sintered parts. A need therefore exists to systematically examine the effect of process parameters on the quality of final parts in order to determine the most appropriate manufacturing parameters for specific applications of copper-based laser sintered parts. This document summarises the effect of different process parameters on the quality of Direct Metal 20 laser sintered parts produced with a EOSINT M250 Xtended laser sintering machine from powder consisting of Ni5Cu, Cu15Sn – Cu5Sn and Cu8P – Cu2P material grains. The quality of the sintered parts is defined in terms of the microstructures, porosities and dimensional deformations obtained. The effects of three different geometric sintering strategies currently in standard use namely Solid Skin, Skin Stripes and Skin Chess were examined, and the more appropriate process parameters and scanning technique for the available set-up is presented. / MIng (Mechanical Engineering), North-West University, Potchefstroom Campus, 2015