All machines from the category Powder nozzle (LENS)

How a metal 3D printer with LENS works

Laser engineered net shaping (LENS) is a 3D printing process that produces metal objects with high precision. This process uses a powerful laser that melts metal powder and applies it layer by layer to create complex components.

The printing process begins with the supply of fine metal powder, which is injected directly into the laser beam via a powder nozzle. The laser beam, which usually operates in the 500 to 4000 watt range, melts the metal powder, which solidifies when it hits the build platform. The desired component is created by repeatedly applying the molten material in layers.

The laser engineered net shaping (LENS) process takes place in an inert atmosphere to prevent oxidation of the material. For more details on the gases used, see below. Thanks to the high precision of lasering, powder nozzle technology can create very fine structures and complex geometries.

Laser engineered net shaping (LENS) can be used to process various metal alloys, including titanium, nickel and cobalt alloys, stainless steel and aluminium. These alloys are frequently used in industries such as aerospace, medicine and automotive engineering due to their strength, corrosion resistance and thermal conductivity.

The big advantage over other 3D printing processes is the ability for Laser Engineered Net Shaping to directly print high-strength metal components and repair damaged metal parts.

Other types of metal 3D printers

On machineselection.com you will find an overview of all 3D metal printing technologies. Other processes include:

• Powder bed technology: selective laser melting (SLM)
• Powder bed technology: electron beam melting (EBM)
• Wire arc additive manufacturing (WAAM)
• Melting nozzle and fused deposition modelling (FDM)
• Powder bonding and binder jetting (BJ)
• Inkjet technology and nanoparticle jetting (NPJ)
• Hybrid machines (application/removal)

Components of a metal 3D printer for laser engineered net shaping

The central components are a powerful laser that melts the metal powder and a nozzle that precisely feeds the powder into the working area. A protective chamber provides an inert atmosphere to prevent oxidation. High-precision movement systems are required to apply the layers precisely. A control unit monitors and controls the entire printing process. Cooling systems regulate the temperature of the laser unit and components. A powder chamber and filter systems complete the LENS system.

Application of laser engineered net shaping in industrial production

Examples of workpieces produced with LENS:

• Aerospace: engine components, turbine blades, housings, structural parts, heat shields and repair parts
• Medicine: implants, hip prostheses, dental prostheses, bone plates and surgical instruments
• Automotive: engine components, transmission housings, exhaust manifolds, turbochargers, brake discs and structural parts

Success factors for laser engineered net shaping (LENS)

As described above, you can process various metals and alloys using powder nozzle technology. What all applications have in common is that the materials are susceptible to oxidation. Processing therefore requires a stable and inert protective atmosphere in the form of gases. These are usually used:

 

For stainless steel: argon or nitrogen

For titanium: argon

For nickel: argon or helium

For aluminium: argon

For cobalt alloys: Argon

 

For all alloys, the purity of the powder is decisive for the quality of the metal 3D printing, which ultimately also determines the mechanical properties of the workpiece. Only use high-purity alloys. Regular monitoring of the metal powder quality ensures consistent printing results.

Of course, the respective material properties with regard to thermal processes also influence processing in laser engineered net shaping (LENS). It is easy for cracks to form and the workpiece to warp, for example, if the workpiece cools down too quickly.

• Stainless steel has a high thermal conductivity, which is why precise temperature control is required.
• Titanium has low thermal conductivity, which makes it necessary to control temperature and cooling rates during printing.
• Nickel alloys have good thermal conductivity and are prone to high thermal expansion, so heat dissipation should be monitored.
• Aluminium also has a high thermal conductivity.
• Cobalt alloys have high strength and heat resistance. Monitor the heat input closely.

Laser strength and layer height are decisive factors for temperature control during laser engineered net shaping. They also determine the density and strength of the component.

Aluminium and cobalt alloys tend to be porous. The metal powder must be kept particularly even and clean. Precise dosing and the right laser power are of great importance in order to produce dense and stable components.

This also includes maintenance tools for cleaning the print nozzles and laser optics.

Leading manufacturers of 3D printers for laser engineered net shaping

In our manufacturers directory, you will find companies that produce metal 3D printers for the powder nozzle / LENS process.

The following terms are often searched for: Colibrium Additive Laser Engineered Net Shaping, EOS GmbH Laser Engineered Net Shaping, 3D Systems Laser Engineered Net Shaping, DMG Mori Laser Engineered Net Shaping

Search now on maschinenauswahl.de for the metal 3D printer that suits your production requirements.