The production of copper parts using DMLR

The relationship between the major process variables (laser power, laser scan speed, scan length, beam overlap and Q‐switch pulse frequency) of direct metal laser re‐melting and their effect on the structure of single‐ and multi‐layer copper coupons has been investigated. The work successfully produced selectively fused copper powder layers and simple three‐dimensional copper structures with suitable laser parameters being identified for the production of parts, including thin‐walled cubic structures. It was shown that the specific energy density needed to melt thick powder beds was less than that to melt multi‐layer builds and that the type of substrate material used significantly affected the process parameters. Thus, the substrate and its thermal properties have a significant effect on the melt pool size and freezing rate.