The production of copper parts using DMLR

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Abstract
The relationship between the major process variables (laser power, laser scan speed, scan length, beam overlap and Q-switch pulse frequency) of direct metal laser re-melting and their effect on the structure of single- and multi-layer copper coupons has been investigated. The work successfully produced selectively fused copper powder layers and simple three-dimensional copper structures with suitable laser parameters being identified for the production of parts, including thin-walled cubic structures. It was shown that the specific energy density needed to melt thick powder beds was less than that to melt multi-layer builds and that the type of substrate material used significantly affected the process parameters. Thus, the substrate and its thermal properties have a significant effect on the melt pool size and freezing rate.