Free Form Fabrication of High Strength Metal Components and Dies

A two-stage method has been devised for free form fabrication of nickel, iron and copper based alloy parts with shape and property control equal or superior to investment castings in the same base alloys. A major advantage of the approach is the ability to utilise commercially available selective laser sintering systems with virtually no modification from their standard configurations for plastic model generation. We have demonstrated the essential feasibility of shape, dimension and property control for complex, low production volume rocket engine components and for tools and dies in higher volume commercial production situations. This presentation is limited in scope to a brief overview of our recent progress.