EOS Has Developed a Solution for Support-Free Metal 3D Printing

Today, metal 3D printing is primarily aimed at professionals, opening up new avenues for them in various industries. Indeed, a study by Grand View Research while the market value in 2022 was already $4.06B, this value is already forecast to reach $22.60B by 2030. DMLS (standing for Direct Metal Laser Melting) in particular stands out. Patented by EOS in 1994, this process is now used in all sectors, including aerospace, medicine and automotive, and combines the advantages of metal 3D printing with excellent and repeatable part quality.

DMLS technology, like other additive manufacturing technologies, also requires support structures (supports). To take the technology a step further and thus realize the full potential for users, EOS has developed a range of solutions that enable metal 3D printing of complex geometries with a drastic reduction of support structures. This is because supports in metal 3D printing are associated with additional time, material as well as effort in post-processing.

Metal printing process on an EOS Quad laser system (photo credits: EOS GmbH)

The Challenges Around Support Structures in Metal 3D Printing

For users of DMLS technology today, it is perfectly normal to have to add supports depending on the desired part. This is because it is only then that one is able to 3D print geometries that have much more complex and detailed designs. This includes, for example, the design of overhangs smaller than 30 degrees, entire bridges or even recesses in the component. All of these geometries would deform without support structures.