SLS Metal Parts Direct from 3D Solid

I'm looking at using 3D Systems Vanguard SLS (Selective Laser
Sintering) process for making injection mold cavity inserts for
preliminary part production. At one time a few years ago the
tolerances and finishes weren't so good. Now I understand they are
far better, but all I have is that relative term "better".

My parts to make are all curved surfaces with virtually no flats
anywhere, and making EDM electrodes even gets to be a bitch. I need a
5 axis mill, or break up the solid into parts for various electrodes.
SLS offers the chance to get the cavity direct, PLUS: INTEGRAL
WATERLINES COME FOR FREE (well, free if I design them into the cavity
insert).

I'm excited about the possibilities, but need more info.

1. Has any SolidWorks users hear-abouts had personal experience
getting high precision metal parts out of the SLS machines?

2. What sorts of tolerances and surface finished have you gotten on
parts under 3" in size?

3. What types of costs have you seen quoted for the SLS parts from
service bureau vendors?

4. Have you used the parts as they come out or have you used them in
heat-treated form? I am considering the LaserForm A6 material.

Info from 3D Systems is at:
http://www.3dsystems.com/products/sls/index.asp
http://www.3dsystems.com/products/sls/vanguard/index.asp

Thanks - Bo Clawson

 

Bo,

Better is a relative term isn't it. About a year ago we had some gears done
out of SST with a bronze filler. We had to bore the center hole concentric
with the pitch axis, but they worked OK after that.

As far as mold cavities/cores, I would suspect you could do something with a
flat parting line. If it's curvy or stepped, it probably (damn likely) won't
be accurate enough to shut off. Finding a feature accurate enough to use as
a datum, to machine the P/L in, is also a problem.

Like I said, it's been a year. If you decide to go for it, let me know how
it works.


Regards

Mark