EOS method for specifying AM parameters

A lightweight turbine cover door hinge for an Airbus A380, laser sintered from EOS Titanium Ti64 powder in 30 - 60 µm layers. (Speed parameters).
A lightweight turbine cover door hinge for an Airbus A380, laser sintered from EOS Titanium Ti64 powder in 30 - 60 µm layers. (Speed parameters).

ExposureEditor is now available for its entire material portfolio, allowing parameter sets to be adjusted. It offers an editing function designed to improve the parameter values in the exposure settings, which can then be run on EOSINT plastic or metal laser sintering machines. Factors taken into account include surface quality, mechanical attributes, accuracy, detail resolution and cost targets. ExposureEditor allows users to meet their specific requirements and implement customised improvements. Only process-critical parameters are protected. EOS says that it is the first AM technology supplier to provide parameter values for the vertical, Z direction as well as in X and Y. Customers are granted additional freedoms through EOS custom parameter sets, which allow for bespoke solutions based on a user's specifications. The customer's intellectual property is protected through a licensing model that allows use and payments to be controlled. The parameter sets are available for direct metal laser sintering on EOSINT M 270 dual mode and EOSINT M 280 systems. Parts produced are dense, and the mechanical and thermal properties are almost identical to those of the solid material. Each metal is assigned one or more parameter sets with corresponding part property profiles (PPPs) which typically include geometric properties such as minimum wall thickness and surface roughness; mechanical properties such as tensile strength, yield strength, elongation at break, modulus of elasticity, hardness and, where applicable, dynamic fatigue life; thermal attributes such as thermal conductivity, specific heat capacity and thermal expansion coefficient, and properties affecting cost such as build-up rates in  mm³/s. Specific values are defined in material data sheets available from EOS on request.

The three EOS parameter sets for metal laser sintering AM applications are:

  • Speed, with 30-60 μm layer thickness for high productivity and good surface quality.
  • Performance, with a 30-40 μm layer thickness, is suitable when the focus is on surface finish, yet offers higher productivity than parameter sets involving thinner layers, helping to reduce production costs.
  • Surface. A 20 μm layer is the lowest thickness and is ideal for parts that require fine and high detail resolution and best surface quality.

PPPs can increase efficiency and reduce costs for data preparation and production planning. The quality assurance department benefits from defined standards and improved transparency, which is important both in prototyping and series manufacture. Three software modules within EOSTATE 1.2 (quality assurance, controlling, and machine park management) provide various reports to meet customer requirements with regard to quality assurance and documentation.

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