3D printing of micro parts takes leap forward

EOS GmbH, a leader in the development of integrated e-Manufacturing solutions in additive manufacturing, and 3D Micromac AG, a provider of highly efficient laser micromachining systems, have collaborated to create Micro Laser Sintering technology (MLS) that has now been commercialized.

The organizations created a new corporation, 3D-MicroPrint GmbH, with the goal of advancing the development and commercialization of the new MLS technology, and to identify and establish more solutions in the field of micro technology. The first system began operating successfully earlier this year at a German research institute.

The collaborative efforts of 3D-Micromac AG and EOS GmbH began in 2006 because of the demand for very small parts that are difficult to manufacture using conventional processes, said Hans Langer, founder and CEO of EOS. "Micro Laser Sintering provides solutions for three major trends: individualization, function integration and miniaturization," Langer said.

Joachim Goebner, CEO of 3D MicroPrint, commented, "Working with layer thicknesses of <30 microns and powder particle size of <5 microns, the MLS technology opens up new dimensions. With MLS it is even possible to produce moveable component assemblies."

Goebner told PlasticsToday that the first system has been commercialized and was sold to a company in Darmstadt, Germany. The basic package consists of the MLS machine, and a glove box to prepare and post process the machine builds. "Additionally, we recommend software from Materialise to do the data preparation from 3D data to layer data, and ultrasonic equipment to clean the manufactured parts. Also, we recommend sieving equipment to recycle the unused powder."

3D MicroPrint's customers can choose to purchase the complete solution, or in the case of companies that already run additive manufacturing equipment, they can pick just the necessary items they need for the MLS process, Goebner noted.

Tino Petsch, CEO of 3D-Micromac AG, added, "Our timing is virtually perfect. The current printing hype shows that our investment in the development of Micro Laser Sintering systems was exactly right. Together, we not offer a trend-setting solution that opens up new approaches in product development and manufacturing for our customers."

Markets anticipated to be served by 3D-Micromac include medical devices for minimally invasive surgery, endoscopy, MRT, and others; jewelry and watches; micro devices, automotive and aerospace industries and moldmaking.

Goebner estimates the market for the MLS technology to be about $5 billion U.S. annually.