SLS 3D printing is increasingly growing in popularity. And when it comes to certain solutions, the benefits can be even clearer. For example, Chinese SLS 3D printer manufacturer TPM3D has clearly shown how its machines can be used to help simply production while making it more efficient. As a result, with this AM process, it is possible to quickly make optimized parts for a wide range of industries.
TPM3D has solidified its reputation in its home country, with its printers being utilized across diverse sectors. Now the company has expanded globally, earning recognition for its large-scale additive manufacturing capabilities and a broad spectrum of materials compatible with SLS 3D printing, such as PA, TPU and PEKK. Notably, TPM3D has carved a niche for itself with its large-format dual-laser industrial SLS systems.
The company’s flagship model, the S600DL, has an impressive build volume of 600×600×800mm, the largest in the market as most SLS 3D printers tend to have small build volumes. This model not only signifies the company’s contribution to streamlining production with SLS 3D printing but also exemplifies its prowess in sectors like medical and automotive.
TPM3D Is Making a Difference in the Automotive Industry
Let’s start with the automotive where TPM3D has served different clients including on different continents. For example, the cases of a self-driving micro police car and improved automotive jig and fixtures.
The police car, from Dubai, is a particularly interesting case. Here the TPM3D S600DL solution was used as well as glass-filled PA12 to make car body parts, structure parts and more. And once again, the value of the company’s SLS 3D printing solutions was seen clearly here as a way to make production more efficient and much simpler. In the traditional method, it was necessary to use a lot of different equipment, including a cutting machine. Then welding would be required. This, as can be expected, resulted in a long lead time for the parts and the car itself had a high weight, with the front part alone weight 27 kg. Hardly ideal for a mini car.
The different stages of developed for the police car from design (left) to the final part (right) with the 3D printed parts highlighted
By turning to SLS and TPM3D, the users were able to significantly simplify the process to just the design and then printing the parts. This brought the lead time down to 2 days, a reduction of about 50%. Not only that, but because of the ability to optimize the design of the parts, the weight of the part was also reduced to only 4kg, reducing it by 82%.
We can see similar benefits with the case of automotive jigs and fixtures in a case from South Korea. Again, the TPM3D S600DL solution and glass-filled PA12 material were used to make a car light fixture, dashboard fixture and bump fixture.
In the original, highly inefficient aluminum process, it was necessary to 3D print a sand mold before actually casting the part. Then it was necessary to break the mold and clean the part after which machining is critical. The final part was then subject to three-coordinate measuring and testing before anodizing.
The worst part? The qualification rate is only 70% to 80% due to issues with sand mold printing failures, casting errors and holes. Adding to that, multiple workers are required for this process, causing high labor costs. By turning to SLS 3D printing through TPM3D, it was possible to greatly simplify the process, improve efficiency and pass rates and reduce costs.
How? Well with 3D printing, for the process, it was just necessary to print the fixtures and depowder them before optional CNC machining and then the three-coordinate measuring and painting. This simplified process also increased the pass rate with fewer steps where issues could arise. You can see more in the table below:
A comparison of cost and time in aluminum casting vs. SLS 3D printing with TPM3D using nylon
Turning to SLS for the Medical Sector
The medical sector is another where TPM3D was able to show its capacity for simplified, efficient production through the improvement of orthotic braces for scoliosis patients. Scoliosis is a condition where a person’s spine has an irregular curve, with severity depending on its degree as well as whether it changes over time. Braces are necessary for treatment in more severe cases.
However, these braces, which are worn between 13 and 16 hours a day, have a number of issues. First, is that the manufacturing of these is complex, with plaster molding, repair, thermoplastic plate attachment, cutting, grinding and lining installation all necessary steps. Not only that, but the resulting product is unattractive as they are large and difficult to hide.
This is where SLS 3D printing comes in. With the TPM3D S360 solution and PA12, it was possible to make a brace significantly faster. Thus, reducing the time from designed to finished product as compared to the cumbersome traditional production process.
SLS 3D printing greatly simplifies the process for making braces for scoliosis, as can be seen in this image
Moreover, the resulting brace was also improved through the use of additive manufacturing. It was possible to make it smaller and easier to hide for less impact on the patient’s daily life, with the added benefit that the correction effect was also better. With these 3D printed braces, the patients’ scoliosis was much improved with a correction rate of more than 50%.
Additional Sectors Benefiting from TPM3D
Of course, these cases do not show all that SLS 3D printing can do. TPM3D has a number of use cases from the aerospace, educational and consumer electronics industries. Similar to automotive and healthcare, users in these sectors have found that adopting additive manufacturing with TPM3D has improved their efficiency and simplified production methods.
Between 3D printed UAV drones that helped bolster the Chinese national market, restoring a 3D printed Megantereon skull to study the ancient beast, 3D printing for electric tools as well as for low-voltage electrical appliances and even sports equipment, among many others, Now, what is undeniable is that TPM3D has shown clearly the wide ways that SLS 3D printing can be adopted.
Indeed, through their solutions, including in the S-Series line, auxiliary machines for cleaner and safer printing and, of course, a wide material range that enables users to choose the desired characteristics of the final part, the company has enabled users to use AM more simply and efficiently. Which, it is safe to say, is exactly what much of the manufacturing world needs. You can learn more about the company at its website HERE.
On the left, the jig made with 3D printing compared to the traditional one on the right.
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*All Photo Credits: TPM3D