Israeli startup has developed a new laser powder bed fusion technology (SLS)

Starting company 3DM from Israel has developed a new laser powder bed fusion technology (SLS) and recently released its first product. It is reported that the new technology developed by this young company established in 2016 will open up the possibility of new materials.

3DM quantum cascade laser
The quantum cascade laser (QCL) stands out in the competition of 3DM in the SLS field. QCL was developed by 3DM founder Daniel Majer (an expert in laser and semiconductor electro-optic technology). It is a semiconductor laser with a high-energy beam that can be tuned to specific wavelengths within the mid infrared spectrum. In fact, this means that 3D printing lasers can be programmed to match the specific melting characteristics of almost any thermoplastic material, opening up huge potential for printing new powder plastic materials. The melting accuracy and intensity of lasers also help to bond material molecules together, resulting in enhanced mechanical and isotropic properties of the parts.

The method of developing lasers that can match the energy absorption characteristics of specific thermoplastic plastics is different from most existing SLS technologies. These technologies often rely on inefficient lasers, which can only handle a small range of materials and materials containing additives to improve energy absorption. This additional development and work may increase the cost of SLS technology and consumables, and limit the feasible range of thermoplastic materials. QCL technology overcomes these obstacles by using lasers to melt specific materials in the most effective way. The QCL technology of 3DM has been successfully used to print all types of SLS materials, including PA, PP, and TPU, and theoretically can be used with any powder based thermoplastic material.

In addition to variable wavelengths, quantum cascade lasers also bring other benefits. The laser is very small, only the size of a grain of rice, and the price is very affordable. According to 3DM, the cost of each tunable wavelength laser is only a few tens of dollars. Therefore, 3DM can develop a beam head system that can economically and efficiently install up to six lasers that can work simultaneously to achieve faster printing speeds (these beam heads themselves can be combined for greater scalability). This laser also has higher accuracy than CO2 lasers and can achieve very high resolution.

Each laser is divided into many laser components, which are then carefully inspected and tested, and assembled together with the collimating lens and driver on a cooling device. Once assembled, these components form the 'laser module'.

Ido Eylon, CEO of 3DM, summarized the main advantages of 3DM laser innovation: The main advantage of QCL technology lies in the melting efficiency of plastic materials. This brings four main benefits: material diversity, high resolution and surface finish, enhanced mechanical properties and isotropy, as well as printing speed and productivity. In addition to these advantages, the expected price points are also cost-effective, and the system is an open platform that allows manufacturers to use multiple materials while maintaining low operating costs.

3DM New Product
In May 2023, 3DM Company is preparing to commercialize two industrial grade 3D printers: a compact professional system equipped with a single laser module, and a large machine equipped with a four laser configuration. The former will be launched first and is an ideal choice for adopters seeking small-scale production and lower entry costs, while the latter is specifically designed for industrial high-throughput applications. Ultimately, the company is most interested in industrial series production.

Four different laser modules are assembled together with other optical components into a shell, which combines all lasers into a high-quality, high-power beam - also known as a beam head (as shown in the figure), producing molten laser points on the powder.
Since May, 3DM has made steady progress in releasing its first system. Eylon represents: We have further stabilized the beam head and made other improvements to it, and have shipped one beam head to strategic partners for testing on their own equipment and facilities. We look forward to this collaboration as it will be the first time 3DM technology has been tested on customer sites and production environments. In addition, we hope to gain a lot of valuable knowledge about additive manufacturing production applications through this event And information. We will apply these insights to future products to make them more suitable for production applications.

3DM has also expanded its agreements with its strategic manufacturing partners to produce its single beam laser heads. Through this latest agreement, 3DM will receive its first prototype system in early 2024. Eylon added, "We expect to launch the product early next year, and due to significant market interest, we have started accepting bookings from selected potential customers to ensure their position in the queue." Next, 3DM plans to launch auxiliary products to supplement its laser powder bed fusion system, including automation and post-processing equipment as well as materials.

Overall view of single beam laser head
Collaborate with service providers
Eylon revealed that 3DM has no intention of becoming a component manufacturer. On the contrary, the company will primarily operate as an additive manufacturing hardware supplier, although it also views itself as an application development consultant as it will work closely with customers and end users to develop materials and applications for its laser powder bed fusion platform.

For services that hope to ultimately integrate 3DM solutions into their production portfolio, Eylon suggests joining the company's strategic partner program and booking their single head machines. He said, "Due to the limited number of units produced in the first batch and the high demand for these units, we encourage manufacturers who want to stay at the forefront of technology to collaborate with us, join the strategic partnership program, understand the potential to provide benefits for their specific situation, and place orders to ensure equipment for next year.

Since entering the market earlier this year, 3DM and its unique products have attracted interest from many industries, including consumer goods, healthcare, automobiles, and defense. Additive manufacturing services have also shown strong interest, and there is no doubt that the company is committed not only to providing a wider range of materials, but also to providing higher quality parts, faster production speed, and more cost-effective 3D printing. The company's focus on high-volume production (with hundreds of thousands of parts) is also key to its market positioning.

3DM has collaborated with many end users to develop applications, materials, and fine-tune its 3D printing technology. Eylon explained, "We continuously collaborate with end users and value their feedback. We plan to implement changes primarily related to output quality, followed by changes related to user experience. Our goal is to manufacture additive manufacturing production systems, which are challenging but exciting.

According to reports, in terms of applications, 3DM companies are most eager to explore use cases that require specific materials to facilitate the tunable wavelength of QCL systems. Eylon said, "The most exciting opportunities are for end users who need specific polymers to achieve their specific applications. We have some confidential examples and have been searching for more.

Source: Antarctic Bear