Laser sintering is a type of 3D printing that uses a high-powered laser to fuse small particles of material, such as plastic or metal powders, together to create a solid object. This process, also known as selective laser sintering (SLS) is often used in the manufacturing industry to produce complex and durable parts.&nbsp;As 3D printing becomes a viable option for manufacturing, the search for a wider range of materials, outside of metal and plastic is essential. <a href="https://sintratec.com/" target="_blank">Sintratec</a>, an innovator within the 3D printing industry, is contributing to the future of additive manufacturing with its Thermoplastic Elastomer material, known as TPE. This material has properties similar to rubber and has wide application in 3D printing from prototyping to end product.&nbsp;<h2 dir="ltr">Sintratec TPE&nbsp;</h2>Sintratec's use of Selective Laser Sintering (SLS) technology enables the transformation of TPE powder into highly precise 3D objects. At a sintering temperature of approximately 110 degrees Celsius, the resulting objects are not only accurate, but also soft to the touch with an impressive degree of stretchability. One of the key features of TPE is its pliability, which can be altered in different areas of a single part by adjusting the wall thickness. This unique characteristic allows for a combination of flexibility and robustness within the same structure, opening up new possibilities for innovative design and application.<iframe width="640" height="360" src="https://www.youtube.com/embed/6v0rn570rtc?&amp;wmode=opaque&amp;rel=0&amp;enablejsapi=1&amp;origin=https://www.wevolver.com" frameborder="0" allowfullscreen="" class="fr-draggable" data-gtm-yt-inspected-10="true" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true"></iframe> <h2 dir="ltr">Distinguishing Features and Efficiency of TPE in 3D Printing&nbsp;</h2>The core feature of TPT printed objects are their high degree of stretchability. Sintratec TPE is recognized for its ductility while ensuring dimensional stability over time. The material showcases a tensile strength of 7 megapascals and a tensile modulus of 21 MPa. Further, its unique features, such as elongation at a break of 448% and a Shore A hardness of 76, set it apart from other materials. Moreover, the economic efficiency of TPE is highlighted by its refresh ratio of 90%, where only 10% of virgin powder needs to be added to the non-sintered material, thereby making it a cost-effective choice in recycling.<h2 dir="ltr">Broad Applications of Sintratec TPE</h2>Sintratec's TPE isn't just for prototypes; it's used in many final products in different industries. Because it's soft and bounces back into shape, it's perfect for dampening or cushioning. This includes parts for bathroom fittings, wrist supports after injuries, and shock absorbers for big machines. You can also find it in bike grips, headphone cushions, and shoes.<h2 dir="ltr">Final Thoughts</h2>Sintratec TPE emerges as a high-performance SLS material well-suited for industrial applications. Its remarkable flexibility, elasticity, and tear resistance cater to various applications, from insulation elements to footwear, making it a versatile choice in 3D printing. As Sintratec continues to explore and introduce more 3D printing materials, the future looks promising for further advancements in <a href="https://www.wevolver.com/article/3d-printing-obsolete-parts" target="_blank">3D printing</a>.<a href="https://sintratec.com/what-is-tpe-an-introduction-to-thermoplastic-elastomer/" target="_blank" rel="noopener noreferrer">This article is based on a video by Sintratec</a>. Read more about Sintratec materials&nbsp;<a href="https://www.wevolver.com/profile/sintratec" target="_blank" rel="noopener noreferrer">here. </a>

A protoptype created with TPE in a laser sintering machine

Thermoplastic Elastomer (TPE) offers a unique balance of flexibility and durability in 3D printing. Utilizing Selective Laser Sintering, it's ideal for various industrial applications, from footwear to machinery dampening.


Flexible, bouncy and durable: TPE adds range to industrial 3D printing.

When it comes to global sustainability, the manufacturing industry is under intense scrutiny to improve its practices. &nbsp;Amidst continuous search for alternatives to greener practices, additive technologies such as <a href="https://www.wevolver.com/article/sls-printing-unlocking-the-potential-of-selective-laser-sintering" target="_blank">Selective Laser Sintering (SLS)</a> has turned out to be a promising technology for the manufacturing industry. It has the potential to transform traditional production lines into eco-friendly models of efficiency. In this article, we will explore how SLS enables manufacturers to meet greener environmental guidelines while maintaining economical efficiency.&nbsp;<h2 dir="ltr">Four Eco-Friendly Benefits of SLS Boosting ROI</h2><h3 dir="ltr">Increased Material Efficiency</h3>SLS enhances material efficiency, unlike the subtractive manufacturing process. It builds objects using only necessary material. Any excess powder not sintered in SLS can be recycled and reused for subsequent prints, reducing waste. If the parts are densely stacked and the software has nesting features to optimize the material usage, the efficiency is further increased. In contrast, subtractive manufacturing starts with a large block, carving away material to form an object. This often results in non-reusable scraps and increased waste.&nbsp;<h3 dir="ltr">Liberty from Tooling Management&nbsp;</h3>Traditional manufacturing methods, whether forging, casting, or injection molding, consistently lean on intricate tooling. These tools – molds, dies, and jigs – come with a heavy overhead. Their production demands substantial financial investment, not to mention the time and energy spent on their design, testing, and refinement. Additionally, the environmental footprint of their fabrication and eventual disposal can't be ignored.With SLS technology, manufacturers <a href="https://utw10945.utweb.utexas.edu/Manuscripts/1991/1991-17-Nutt.pdf" target="_blank" data-lf-fd-inspected-kn9eq4roawkarlvp="true">bypass the entire tooling phase</a>. The complex 3D object springs directly from digital blueprints, without any molds or support structure, streamlining the production pipeline immensely. There's no longer a need for large storage areas for tools or the continual upkeep and repair costs associated with wear and tear. Furthermore, the freedom to transition seamlessly from a digital model to a physical product paves the way for intricate designs previously thought unachievable.<h3 dir="ltr">Prevent Overproduction and Decrease Scrap</h3>Mass production, with its inevitable inventory build-ups, often results in overproduction. Such excess not only ties up resources but also contributes to a significant amount of waste when unsold products become obsolete. However, with the on-demand customized production capability of SLS, manufacturers can prevent overproduction, optimize inventory storage, and decrease scrap with ease.&nbsp;By preventing overproduction, we can reduce the waste and ecological harm stemming from both production and disposal of surplus goods. Additionally, the ability to produce parts locally with SLS further drastically reduces carbon emissions associated with long-distance shipping that eventually increases carbon footprint in the atmosphere.&nbsp;<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1697727294303-sintratec-kit-part-4.jpg" style="width: 300px;" class="fr-fic fr-dib">SLS printing enables complex geometries with loewr waste. Image credit: Sinatrec.<h3 dir="ltr">Multi-Use Plastics</h3>Selective Laser Sintering has the potential to pivot the industry from single-use plastics to durable, multi-use options.Traditional manufacturing frequently employs injection molding to create single-use plastic items. This method efficiently produces large quantities of identical products. However, these short-lived items quickly become waste, significantly amplifying the global plastic pollution problem.In contrast to traditional methods, SLS harnesses the power of lasers to sinter polymer powders layer by layer, crafting parts with superior strength and precision. These high-quality polymer parts are inherently more durable, reducing their wear and tear over time, leading to a reduction in the overall generation of plastic waste. Also, <a href="https://www.wevolver.com/article/the-guide-to-selective-laser-sintering-sls-post-processing" target="_blank">SLS post-processing options</a> are eco-friendly and ensure appearance and functionality of the component are top-notch.Moreover, one of the significant hurdles is in sourcing spare parts for outdated machinery, making replacements a daunting task. However, <a href="https://www.wevolver.com/article/3d-printing-obsolete-parts" target="_blank">3D printing</a> can replicate these parts with precision with a wide range of industrial-grade materials, ensuring a seamless fit and high shelf life of the machinery.<h2 dir="ltr">Conclusion</h2>3D printing and SLS are greener manufacturing practices with numerous benefits. Manufacturers can leverage SLS to reduce material waste, eliminate unnecessary tools, meet on-demand production, and promote recycling, without hurting their production line. In the long run, it helps industries position themselves at the forefront of innovation and sustainability, crafting a future for the next generation where efficiency and ecology go hand in hand.

Object printed in laser sintering machine

SLS 3D Printing: An Eco-Friendly 3D manufacturing solution that reduces waste and energy use while enabling on-demand production and quick customization

Selective Laser Sintering: Bridging the Gap to Sustainable Innovations

<a href="https://www.xometry.de/en/sheet-metal" target="_blank">Sheet metal fabrication</a> is the process of turning flat sheet metals, typically 0.15 mm to 10 mm thick, into parts and structures of various shapes. The stock materials for this process are flat metal sheets. Sheet metal fabrication is used to create objects such as enclosures, chassis, brackets, stamped features, curls, etc. It is also used for decorative purposes to make patterns in metal sheets.<h2>How Does Sheet Metal Fabrication Work?</h2>The transition from stock material to the finished product usually requires one or more of the following three processes: material removal (cutting), deforming, and assembly. If all these processes are required, they are usually performed chronologically.<h3>Material Removal</h3>This involves cutting out pieces of the stock material to produce the desired shape. For maximum accuracy, speed, and efficiency CNC waterjet, plasma, and laser cutting technologies are usually employed. <a href="https://en.wikipedia.org/wiki/Electrical_discharge_machining" target="_blank">EDM</a> (electrical discharge machining) could be also an option in some cases.<h4>Laser Cutting</h4>In <a href="https://www.xometry.de/en/laser-cutting" target="_blank">laser cutting</a>, a high-density laser beam is directed onto a workpiece to melt, vaporise, or burn through it, effectively cutting the material. Laser cutters are used for cutting, boring, and engraving. There are three types of lasers used in laser cutting; CO2 (carbon dioxide), Nd (neodymium), Nd:YAG (neodymium-doped yttrium aluminium garnet).CO2 lasers have high energy efficiency and high power output ratio, and are used for cutting thin material, engraving, and boring. Nd lasers have high energy but low repetition efficiency. They are used for engraving, boring, and welding. Nd:YAG lasers have a very high power output and can cut thicker materials. However, they are more expensive to operate than CO2.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1691147537942-laser-cutting.gif" style="width: 766px;" class="fr-fic fr-dib">Laser cutting process (Sudobob.com)Laser cutters can work with aluminum, steel, copper, stainless steel, and other metals. They are best used for cutting thin workpieces (maximum thickness of 15 mm for aluminium and 6 mm for steel), engraving, and boring<h4>Water-Jet Cutting</h4>In water-jet cutting, a nozzle is used to focus a jet of water at very high pressures to cut a workpiece. For relatively soft material like rubber and wood, only water is used. A mixture of water and abrasive granular substances is used to cut harder material such as metals.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1691147560465-waterjet-cutting.gif" style="width: 766px;" class="fr-fic fr-dib">Waterjet cutting process (gyfcat.com)<a href="https://www.xometry.de/en/waterjet-cutting" target="_blank">Water-jet cutting</a> can cut material of various thicknesses. The maximum thickness that can be cut depends on the material. Of all CNC cutting methods, waterjet cutting is the most precise with tolerances between 0.05 mm and 0.1 mm. One of the reasons for its high precision is that unlike plasma and laser counterparts, waterjet cutting does not generate heat hence there is no heat affected zone in the workpiece.Waterjet cutting is very versatile as it is used to cut hard material such as aluminum, steel, copper, stainless steel, and other metal alloys as well as softer materials like polymers, elastomers, wood, and foam.<h4>Plasma Cutting</h4><a href="https://www.xometry.de/en/plasma-cutting" target="_blank">Plasma cutting</a> works by applying heat and energy to a gas to turn it to plasma. A jet of hot plasma is then accelerated using an inert gas or air, out of the cutting nozzle and onto the workpiece. The plasma completes an electrical arc with the workpiece, melting and cutting it. Being an electrical process, plasma cutters only work with electrically conductive material.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1691147582283-plasma-cutting.gif" style="width: 766px;" class="fr-fic fr-dib">Plasma cutting process (gyfcat.com)Plasma cutters&nbsp;can cut through very thick material, up to 300 mm for aluminum and 200 mm for steel, with a tolerance of 0.2 mm. Other materials that are processed using plasma cutters are stainless steel, copper, and other metal alloys. Depending on the complexity of the part to be produced, 2-axis or 3-axis cutters may be used.Although plasma cutters are not as diverse or precise as waterjet and laser cutters, they are the best choice for thick electrically conductive metal parts, as they are faster and more cost-effective for cutting such materials.<h3>Deforming</h3>This process is the controlled application of force to bend or form sheets into desired shapes. Deforming processes included bending, forming, stamping, and stretching using dies as well as hydraulic and magnetic brakes.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1691147611216-iStock-917091108-e1591293772304.jpg" style="width: 766px;" class="fr-fic fr-dib">Bending process<h3 id="isPasted">Assembling</h3>This is the process of joining various processed workpieces together to form a final product. Assembling processes include welding, brazing, riveting, and sometimes, the use of adhesives.<h2>Materials</h2>The most suitable metals for this process are aluminium and its alloys, steel, copper and its alloys, and stainless steel.&nbsp;The table below contains the most popular metal grades for sheet metal fabrication.<figure><table><tbody><tr><td>Aluminium</td><td>Copper</td><td>Stainless steel</td><td>Steel</td></tr><tr><td>DIN 3.3523 | EN AW5052</td><td>DIN 2.0065 | EN CW004A</td><td>1.4319</td><td>Mild steel</td></tr><tr><td>DIN 3.3211 | EN AW6061</td><td>DIN 2.0265 | EN CW505L</td><td>1.4301</td><td>Low-carbon steel</td></tr><tr><td>DIN 3.3535 | EN AW5754</td><td>DIN EN 13601 | EN CW009A</td><td>1.4404</td><td>&nbsp;</td></tr></tbody></table></figure> Post-processing OperationsCommon post-processing operations used in sheet metal fabrication are bead blasting, anodizing, powder coating, and painting. For deformed or welded materials, heat treatment is carried out to relieve residual stresses.<h2>Benefits of Sheet Metal Fabrication</h2>Some of the benefits of sheet metal fabrication are as follows.<ul><li>Durability: The process produces highly durable products for both prototyping and end-use</li><li>Scalability and cost-efficiency: &nbsp;Whether you need a single one-off part or a production run of thousands of parts, sheet metal fabrication provides a fast and cost-effective solution.</li><li>Material selection: Numerous metals can be processed via this method of fabrication. You can choose from hundreds of metals with varying desirable properties.</li><li>Rapid turnaround: The use of CNC technologies for sheet metal fabrication makes the process fast and effective</li></ul><h2>Industries that Employ Sheet Metal Fabrication</h2>Any industry that makes use of metal parts would likely find the need for sheet metal fabrication. Some of the industries which employ the process are<ul><li>Machine building</li><li>Engineering and design</li><li>Metalworks</li><li>Electronics</li><li>Furniture and city infrastructure</li><li>Robotics</li><li>Medical and healthcare</li><li>Automotive</li><li>Musical instruments</li><li>Civil construction</li></ul><h2>Conclusion&nbsp;</h2>At Xometry Europe we offer high-precision, fast and quality <a href="https://www.xometry.de/en/sheet-metal" target="_blank">sheet metal fabrication services</a> for the creation of parts out of sheet metal such as aluminium, steel, copper alloys and many others. Using automated cutting technologies such as CNC laser cutting, plasma cutting, water-jet cutting as well as deforming and assembling technologies, we guarantee high precision and quality of ready parts.We also carry out post-processing upon your request. To get an instant quote, upload your models on our <a href="https://my.xometry.de/enquiries/new" target="_blank">instant quoting</a> platform.

Sheet metal fabrication is the process of turning flat sheet metals, typically 0.15 mm to 10 mm thick, into parts and structures of various shapes. The stock materials for this process are flat metal sheets. Sheet metal fabrication is used to create objects such as enclosures, chassis, brackets, stamped features, curls, etc. It is also used for decorative purposes to make patterns in metal sheets.

Introduction to Sheet Metal Fabrication

3D printing is a well-known Additive Manufacturing technique, it can create three-dimensional objects by depositing materials layer by layer. Processes such as SLA (stereolithography) and DLP (digital light processing) are in particular known for high precision and resolution. While it is compatible with various materials, including polymers, metals, and ceramics, and commonly used in rapid prototyping as it enables fast design iterations, it may not achieve the same level of precision as other techniques such as Electroforming and lacks the capacity for high volume production runs.&nbsp;<a href="https://insights.vecoprecision.com/electroforming-vs.-3d-printing-whats-the-difference" rel="noopener" target="_blank">-&gt; Learn more about the comparison of Electroforming and 3D Printing</a>Laser Cutting uses focused laser beams to cut through materials, creating precise patterns and shapes. With Laser Cutting, intricate patterns with tight tolerances can be achieved. Although there are other advantages such as high precision and a wide range of compatible materials, it also has some limitations, such as HAZ (heat affected zones) which is thermal damage from the laser process.<a href="https://insights.vecoprecision.com/electroforming-vs.-laser-cutting-whats-the-difference" rel="noopener" target="_blank">-&gt; Learn more about the comparison of Electroforming and Laser Cutting</a>Micro Milling is a Subtractive Manufacturing process that involves the removal of material using rotating cutting tools with very small diameters. This technique works with various materials, such as metals, ceramics, and polymers, and can achieve tight tolerances and smooth surface finishes. On the other hand, due to its vibration/rotating feature, an additional process for stabilization might be required when high precision cannot be compromised.<a href="https://insights.vecoprecision.com/large-volumes-small-parts-a-comparison-between-electroforming-and-micro-milling" rel="noopener" target="_blank">-&gt; Learn more about the comparison of Electroforming and Micro Milling</a>Micro punching uses robust &lsquo;masters&rsquo; to punch holes in (mostly metal) substrates. As nozzle specifications have ever tighter tolerances, fewer masters can be used in parallel to reduce the variation. This slows down the production process while increasing the price.<a href="https://www.vecoprecision.com/electroforming/" rel="noopener" target="_blank">Electroforming</a>&nbsp;is an additive manufacturing method that combines lithography with highly controlled electrodeposition which is highly suitable to create metal parts with micro holes of any shape. The lithography allows for small feature sizes with tight tolerances while electrodeposition grows a large number of parts in parallel without local damage or deformations. By combining several lithography and electrodeposition steps Electroforming can also integrate micro nozzles with channels, distance holders, or filtration structures.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjg2MTIzODU4Nzg5LVNjcmVlbnNob3QgMjAyMy0wNi0wNyBhdCAxNS40MS41OS5wbmciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 766px;" class="fr-fic fr-dib">Examples of electroformed nozzles&nbsp;When comparing 3D printing, Laser Cutting, Micro Milling, and Electroforming, many factors come into play. The choice of technology for producing micro-fabricated nozzle plates depends on the specific requirements of the application and the desired characteristics of the final product. Here we compare 4 key factors: Precision, Customization, Scalability, and Material capability.Precision: Electroforming offers the highest precision and accuracy, down to the sub-micron level, making it ideal for intricate structures and fine features. Laser cutting and Micro Milling offer good precision but may not achieve the same level of detail as Electroforming. 3D printing provides moderate precision, depending on the specific technology used (SLM, EBM, etc.).Customization: Electroforming allows for a high degree of customization, enabling the creation of complex geometries tailored to specific applications and the integration of additional functionalities such as channels into a single part. Laser cutting and Micro Milling also offer customization capabilities, but their potential may be limited by the complexity of the desired design. 3D printing provides the greatest design freedom, allowing for the creation of complex geometries and internal structures that may be challenging or impossible to achieve with other methods.Scalability:&nbsp;Electroforming is well-suited for large-scale production due to its high repeatability and consistency across multiple production runs. Laser cutting offers a moderate level of scalability, depending on the specific setup and materials used. Micro Milling and 3D printing are better suited for small-scale production or rapid prototyping, as their efficiency may decrease in larger-scale applications.Material Compatibility:&nbsp;Electroforming is focused explicitly on metal deposition, making it suitable for producing metal nozzle plates. Laser cutting and Micro Milling are also adaptable to a wide range of materials, such as metals, plastics, and ceramics. 3D printing can work with different materials depending on the specific technology, with metal 3D printing techniques like SLM and EBM being particularly relevant for nozzle plates.In conclusion, Laser cutting, and Micro Milling provide normal precision and flexibility for applications not driven by extreme accuracy, while 3D printing offers unparalleled design freedom and material efficiency but is not comparable in precision. Electroforming excels in precision, customization, and scalability, making it particularly suitable for high-resolution and large-scale applications.Electroforming: Additive Manufacturing atom by atom<a href="https://www.vecoprecision.com/electroforming/" rel="noopener" target="_blank">Electroforming</a> is an advanced Additive Manufacturing technology specialized for producing <a href="https://www.vecoprecision.com/products/" rel="noopener" target="_blank">high-precision metal parts</a>. Its uniqueness is that you can grow metal parts atom by atom, providing extreme accuracy and high aspect ratios. This process involves the use of an electric current to deposit layers of metal onto a substrate or mold, resulting in a highly accurate and precise reproduction of the original shape.There are several key benefits that make Electroforming particularly well-suited for the production of <a href="https://www.vecoprecision.com/products/micro-nozzle-plates/" rel="noopener" target="_blank">micro-nozzle plates</a>. Micro-nozzle plates require a high degree of accuracy and precision to function properly, and the Electroforming process can achieve this level of precision with a high degree of consistency. In addition, the Electroforming process is able to produce complex shapes with a high level of detail, which is critical in the production of micro-nozzle plates. These plates typically include a large number of very small nozzles, which require a high degree of accuracy and precision in order to function properly. Finally, Electroforming is a highly efficient and cost-effective manufacturing process, which is important in producing micro-nozzle plates. These plates are typically used in high-volume applications, where the ability to produce large quantities of parts quickly and efficiently is critical.<a href="https://insights.vecoprecision.com/cs/c/?cta_guid=8681c2ee-0a4a-407d-9e8c-85b23a7efd3f&signature=AAH58kEMSQR3cdQZ8AGE7ZNxiT4RQ2CXcQ&pageId=112575129227&placement_guid=056f005b-1e5e-49f9-b6d2-99830614eb56&click=a5ddf881-0995-423e-accb-0f06b9110c8c&hsutk=97710d8cef260b164f288d3460335fe3&canon=https%3A%2F%2Finsights.vecoprecision.com%2Fthe-making-of-micro-precision-nozzle-plates-3d-printing-laser-cutting-micro-milling-and-electroforming-compared&portal_id=1788947&redirect_url=APefjpGd17WwmSDSm36cLF2XSoWjfQRHaa43B7la0_L-iM6yd-D3msMSyL_7WOcYhUunyYIO9Rnsyy6LZCiOKrgHSMm8dby6zx5aCkXoasfmrsiuGZ_KHd0HAKKcBiFDkw-30qOT32Hm9umHkcLDapHM6Z8qhrUHjo-Q6ZwFjNpCD86sdetQ8OV3iMLhYUCkyjf5p_sMHhOL_paAFhBBOh4FWI4QEgFpDxhInOyzVBM5W8zyCK_WZyamYi8Cb3kQp3UEpbm9qCgC_E0gLpsxb4dPtklv9wwWrXyHKsRtHYAk440OnPMAonY&__hstc=207439628.97710d8cef260b164f288d3460335fe3.1683536443459.1686041795655.1686123279027.13&__hssc=207439628.3.1686123279027&__hsfp=2288638424&contentType=blog-post" rel="noopener" target="_blank"><img alt="New Call-to-action" src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjg2MTIzODIyNDI1LTE2ODYxMjM4MjI0MjUucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" class="fr-fic fr-dii"></a>

Micro-fabricated nozzle plates are used in various industries, such as inkjet printing, medical devices, and flow control. Manufacturing these nozzle plates requires precision and accuracy to achieve the desired performance. Several production technologies can be used to manufacture micro-fabricated metal nozzle plates, such as 3D printing, Laser Cutting, Micro Milling, Micro Punching, and Electroforming. 

In this article, we will introduce these production technologies, and illustrate how to find your preferred process for the production of micro-fabricated nozzle plates based on key features such as precision, customization, scalability, and material compatibility.

The making of micro-precision nozzle plates: 3D Printing, Laser Cutting, Micro Milling, Micro Punching, and Electroforming compared

Laser Cutting is a subtractive manufacturing process. It works by directing the output of a high-power laser most commonly through optics to cut materials in order to achieve the desired products. Compared to Laser Cutting, Electroforming is the more optimal choice when it is large volume production of precision thin metal parts, especially when the design is complex and quality/accuracy demand is high. So what&#39;s the difference between these two precision manufacturing techniques?<h3 id="isPasted">(1) Cost Efficiency</h3>When it&rsquo;s a small volume production or prototyping, Laser Cutting can be more cost-effective than&nbsp;<a href="https://www.vecoprecision.com/technologies/electroforming" rel="noopener" target="_blank">Electroforming</a>. When it&rsquo;s industrial mass production, however, Laser Cutting loses its advantage in costs and Electroforming becomes the favorable option.<h3>(2) Lead Time</h3>With Laser Cutting, you can&rsquo;t produce multiple parts simultaneously, while with&nbsp;<a href="https://www.vecoprecision.com/technologies/electroforming" rel="noopener" target="_blank">Electroforming</a> you can. Compared to Laser Cutting, which can only deal with one component after another, Electroforming is a process that can harvest a large number of products in every run. When production volume is very low, Laser Cutting might have an advantage in speed over Electroforming. However, when it is industrial production, the lead time of Electroforming is shorter.<h3>(3) Design Complexity</h3><a href="https://www.vecoprecision.com/technologies/electroforming" rel="noopener" target="_blank">Electroforming</a> and Laser Cutting are both highly flexible regarding design. When the design is very complex, however, Laser Cutting might take a much longer time since it can only deal with one part/feature after another while Electroforming works on the complete design simultaneously and can harvest a large amount of product in one run. When it comes to materials, Electroforming has some limitations while Laser Cutting can work with a wider range of materials&nbsp;<a href="https://insights.vecoprecision.com/what-materials-can-be-electroformed" rel="noopener" target="_blank">(learn more about what materials can be electroformed from a previous blog)</a>.<h3>(4) Quality/Accuracy</h3><a href="https://www.vecoprecision.com/technologies/electroforming" rel="noopener" target="_blank">Electroforming</a> is a high-precision manufacturing process that does not change the properties of metals such as hardness, grain structure, or ductility. With Electroforming, you can harvest&nbsp;<a href="https://www.vecoprecision.com/precision-products" rel="noopener" target="_blank">ultra-precision thin metal parts burr- and stress-free</a>. Laser Cutting, on the other hand, is a thermal process that results in thermal stress, as well as micro burrs.Thus, compared to Laser Cutting, Electroforming is the more optimal choice when it is large volume production of precision thin metal parts, especially when the design is complex and quality/accuracy demand is high. When it is about material choice, Laser Cutting has the advantage over Electroforming.To learn more about the benefits of Electroforming, and how it can drive continuous innovation for you as an engineer,&nbsp;<a href="https://insights.vecoprecision.com/en/whitepaper-electroforming" rel="noopener" target="_blank">download the Whitepaper Electroforming here</a>.&nbsp;

What's the difference of these two precision manufacturing techniques? This article will review on Cost Efficiency, Lead Time, Design Complexity, and Quality/Accuracy.

Electroforming vs. Laser Cutting: What's the Difference?

Partner:<a href="https://kopr.net/en/homepage/" target="_blank">KOPR spol. s.r.o.</a>&nbsp;&nbsp;Problem:Before the implementation of an automation solution, 3 different types of heavy hot-formed parts needed to be loaded manually into a fixture for laser cutting. The cutting process was then followed by a 100% visual check for the completeness of the cut. This work was very hard for an operator from an ergonomic point of view. In addition, there was a high cost per part for the company and unsatisfactory overall equipment effectiveness (OEE) due to a significant time loss on the operator’s side. Therefore, the customer decided to automate the process.&nbsp;Solution:<a href="https://www.photoneo.com/phoxi-3d-scanner/" target="_blank">PhoXi 3D Scanner XL</a> +&nbsp;<a href="https://www.photoneo.com/bin-picking-studio/" target="_blank">Bin Picking Studio</a>The whole handling process got completely automated with a bin picking solution from Photoneo. The operator has been replaced by an ABB 6650s 6-axis robot with a universal gripper that can pick all three different products from a container and place them in a fixture. Afterward, the robot takes them from the fixture and places them in output boxes. A 100% check for cut completeness has been implemented as well.There are 2 input boxes, each containing a container with the dimensions of 2.2 x 1.2 m. The parts are stacked up reaching a height of 1.5 m. The solution deploys the Photoneo Bin Picking Studio with two PhoXi Scanners models XL, one for each box. The robot automatically chooses the container from which it needs to take out the parts. The PhoXi 3D Scanner makes a scan while the robot handles parts in the other box so that the robot does not lose any time while changing the boxes.The whole bin picking solution consists of scanning, parts recognition, and collision-free trajectory computation. In addition, there is a tailor-made error-handling running in the robot as a parallel background task to prevent time loss in case the containers get empty or any other kind of error.&nbsp;Discussion:Besides the very good bin picking performance during both the day (ambient light) and night (dark hall), the customer appreciates the user-friendly customer interface allowing to easily set up a new product without Photoneo’s assistance.&nbsp;It was a challenging task to force a specific trajectory of the robot for going in and out of the container but the system can always adapt to newly recognized parts while each container is a bit different due to the welded supports inside. The Photoneo system does the job 100% precisely while avoiding collisions with point clouds.The major advantage of the automation solution is a significant increase of the process OEE (about +8%!) while making the process stable, efficient, and reliable, with less downtime of the whole laser cutting. This resulted in a reduced price per part for the customer while working in a much more convenient way. In addition, thanks to the robotic handling of heavy parts with high precision achieved by Photoneo, the parts do not fall from a height on the fixture anymore. This reduces fixture maintenance in comparison to previous manual handling.The application has been running for about a year in a 24/7 production, and it is a successor to 10 automation solutions built in the past in a similar way with different products and setups.

KOPR spol. s.r.o. developed a solution for advanced laser cutting of heavy hot-formed parts and their subsequent quality check. The solution deploys 3D vision and Bin Picking Studio from Photoneo and an ABB robot.

Automated laser cutting of heavy parts

Laser cutting is the process of using a laser beam to vaporize, melt, or otherwise gradually remove material. Computer Numerical Control (CNC) laser cutting commonly uses optics, an assist gas, and a guidance system to direct and focus the laser beam into the workpiece. The many benefits of CNC laser cutting include:<ul><li>Speed.</li><li>Less waste.</li><li>Broad Range of Materials.</li></ul>Although laser cutting has been used industrially since the early 1970s, CNC laser cutting has recently become the production tool of choice in makerspaces, in schools, and with hobbyists.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjA0NTE0NDA0NDQ2LUFkb2JlU3RvY2tfMjYxODAxOTM5LTEwMjR4NjgzLmpwZWciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19">CNC laser cutting through thin sheet metal.&nbsp;<h2>How CNC Laser Cutting Works</h2>Laser beams are generated by electrically exciting a lasing material. This beam is internally reflected and amplified inside its container with a partial mirror. Once it has generated enough energy to escape the container, it may be focused towards the workpiece. Three main types of lasers are used for CNC laser cutting:<ol><li>Carbon dioxide (CO₂)</li><li>Neodymium-doped yttrium aluminum garnet (Nd:YAG, or YAG)</li><li>Fiber</li></ol>CO₂ and YAG lasers are similar in construction but are used differently. C0₂ lasers with lower power levels are used for engraving, while ones with higher power levels are used in industrial applications for welding and cutting because of their reasonably low price. YAG lasers, with their higher peak output, yield exceptional results for metal marking and etching. Fiber lasers, with their solid-state construction and high-power output, reduce consumable costs and effectively cut a wide variety of materials.<h2>Why Use CNC Laser Cutting?</h2>CNC laser cutting features:<ul><li>Faster processing and production times.</li><li>Minimal warping.</li><li>Greater accuracy when compared to flame or <a href="https://prototypehubs.com/what-is-cnc-plasma-cutting/" rel="noopener noreferrer" target="_blank">plasma</a> cutting.</li><li>More parts per sheet of material due to the laser beam’s small cutting diameter (kerf).</li><li>Great for thing materials, but thicker and denser materials may be cut by replacing the collimating lens in order to change the laser’s focal point.</li></ul>CNC laser cutting has many advantages over flame, <a href="https://prototypehubs.com/what-is-cnc-plasma-cutting/" rel="noopener noreferrer" target="_blank">plasma</a>, and waterjet cutting methods. As the laser’s heat application is tightly focused, it requires less power and the material’s heat-affected zone (HAZ) is reduced. Many high-end industrial laser cutting machines are accurate to 10 micrometers and have a repeatability of 5 micrometers. CNC lasers can affordably cut and etch a wide variety of materials, even the non-metallic materials that typically cannot be cut by flame or plasma processes.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjA0NTE0NDUxOTM0LUFkb2JlU3RvY2tfMjM5MzkwMDA4LTEwMjR4NjgzLmpwZWciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19">Lasers can cut various materials, including natural materials like leather.&nbsp;<h2>Choosing CNC Laser Cutting</h2>With the rise of the maker, do-it-yourself (DIY), and hobbyist communities, CNC laser cutting continues to surge in popularity. The broad range of cutting capabilities and superior dimensional accuracy make CNC laser cutting an ideal manufacturing tool for end users. Read more about how CNC laser cutting could work for you on our <a href="https://prototypehubs.com/cnc-cutting" rel="noopener noreferrer" target="_blank">Customized CNC Cutting Services</a> page.

Laser cutting is the process of using a laser beam to vaporize, melt, or otherwise gradually remove material. Computer Numerical Control (CNC) laser cutting commonly uses optics, an assist gas, and a guidance system to direct and focus the laser beam into the workpiece.

laser cutting

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