Shenzhen Alu Rapid Prototype Precision Co., Ltd.

Additive Manufacturing (AM), or 3D printing, builds three-dimensional objects by adding material layer by layer based on a digital model. Unlike traditional subtractive methods (e.g., CNC machining, which removes material), AM constructs parts directly from a CAD file, offering flexibility and efficiency. 

How Additive Manufacturing Works

Design Creation

Process: A 3D model is created using CAD software (e.g., SolidWorks, Fusion 360) or 3D scanning. The design is optimized for AM, considering factors like support structures or material properties (Design for Additive Manufacturing, DfAM).

File Format: The model is exported as a compatible file, typically STL, STEP, or 3MF, for processing by AM software.

Shenzhen Alu Rapid’s engineers can assist with DfAM to optimize designs for technologies like SLM or DMLS.

File Preparation (Slicing)

Process: The 3D model is imported into slicing software, which divides it into thin layers (typically 20–100 microns thick, depending on the technology). The software generates toolpaths, support structures, and printing parameters (e.g., laser power, layer thickness).

Output: A machine-readable file (e.g., G-code) is created to guide the AM system.

Shenzhen Alu Rapid’s AI-powered platform (https://www.aluprototype.com) automates slicing and setup for efficient production.

Material Selection

Materials vary by AM technology and application, including:

Metals: Titanium, stainless steel, aluminum, Inconel (used in SLM, DMLS, EBM, Binder Jetting).

Polymers: ABS, PLA, nylon (used in FDM, SLS).

Resins: Photopolymers (used in SLA).

Composites: Carbon-fiber-reinforced materials.

Example: Shenzhen Alu Rapid offers a wide range of metals and polymers, tailored for industries like aerospace or medical.

Printing Process

The AM system builds the part layer by layer using one of several technologies:

Powder Bed Fusion (PBF): A laser (SLM, DMLS) or electron beam (EBM) melts metal powder in a controlled atmosphere or vacuum. Common for high-precision aerospace parts.

Directed Energy Deposition (DED): Melts metal powder or wire as it’s deposited, ideal for repairs or large components.

Binder Jetting: Applies a binding agent to metal or sand powder, followed by sintering in a furnace for density.

Metal Extrusion: Extrudes metal-infused filaments, requiring post-sintering for full strength.

Fused Deposition Modeling (FDM): Extrudes melted plastic filaments for polymer parts.

Stereolithography (SLA): Cures liquid resin with a laser for high-resolution polymer parts.

Selective Laser Sintering (SLS): Fuses polymer powder with a laser for durable plastic parts.

Each layer is fused or bonded to the previous one, gradually forming the complete part.

Example: Shenzhen Alu Rapid uses SLM to print titanium medical implants with precise control over layer fusion.

Post-Processing

Support Removal: Supports (used in SLM, DMLS, or FDM) are removed via cutting, machining, or dissolution.

Finishing: Parts may undergo heat treatment (e.g., stress relieving for SLM), sintering (Binder Jetting), polishing, or CNC machining for smoother surfaces or tighter tolerances.

Inspection: Dimensional accuracy and quality are verified using tools like CMM or X-ray, ensuring compliance with standards.

Shenzhen Alu Rapid integrates CNC machining and surface finishing to deliver production-ready parts.

Testing and Application

The finished part is tested for fit, function, or performance (e.g., stress testing for aerospace components).

If needed, the design is revised, and the process repeats for optimization.

Parts are used for prototyping, production, or repairs in industries like aerospace, medical, or automotive.