Industrial freeform generation of microtools by laser micro sintering

Abstract

Purpose

Examples are given for the technical applicability of a novel development of selective laser sintering called “laser micro sintering”.

Design/methodology/approach

Together with a specific method to produce powder layers, the controlled application of pulsed radiation for the processing of sub‐μm grained metal powders was exploited to produce micro‐tools with a heretofore unattained structural resolution.

Findings

High resolution micro bodies are displayed. Instruments could be generated which proved to fulfil their designation as grip bits for micro manipulators. The micro‐bodies can be generated detachably from or firmly fixed to the construction substrate. The material of the generated bodies withstands the traction forces when used as an injection mold for polymer casts.

Research limitations/implications

Densities and structural resolutions can still be improved especially with a newly updated version of the equipment. Laser micro sintering of materials, other than metal (e.g. ceramics), has still to be developed. The introduction of the equipment and the technique into the market is on its way.

Practical implications

Micro‐tools can be generated with an overall structural resolution of 30 μm and with all the advantages of a freedom technique.

Originality/value

The paper informs the technical community on a new novel modification of the freeform technique selective laser sintering, demonstrating the solution of some problems that have hampered the progress of metal laser into resolution ranges below 100 μm. It also supplies evidence for the technical applicability.

Citation

Regenfuss, P., Hartwig, L., Klötzer, S., Ebert, R., Brabant, T., Petsch, T. and Exner, H. (2005), "Industrial freeform generation of microtools by laser micro sintering", Rapid Prototyping Journal, Vol. 11 No. 1, pp. 18-25. https://doi.org/10.1108/13552540510573356