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DTM Nearing Completion of Beta Testing on New Metal SLS Material

30 August 2000

DTM Nearing Completion of Beta Testing on New Metal SLS(R) Material DTM LOGO DTM logo. (PR NewsFoto)[AS] AUSTIN, TX USA 08/05/1998    

 LaserForm(TM) ST-100 Expands Rapid Prototyping to Metal Part and Tool Making
                    Applications, Low Volume Manufacturing

    AUSTIN, Texas, Aug. 29 DTM Corporation is
nearing the end of the first phase of beta testing for its new LaserForm(TM)
ST-100 material.  The ability to process this metal material gives DTM a
distinct advantage over many other prototyping methods, and promises to widen
the market for DTM's Sinterstation(R) systems and SLS materials, which have
primarily been used to create functional plastic parts.
    LaserForm ST-100, a 420 stainless steel alloy, will allow companies to
further speed the production of fully dense metal prototypes and end-use
parts.  LaserForm can also be used to create complex tooling inserts for
injection molding.  The material produces parts with investment casting
tolerances and tooling with excellent "as-processed" surface finish.
    The new material is nearing the end of its first beta testing phase with
several DTM customers, including Valeo Sylvania of Seymour, IN, USA; Bastech,
Inc. of Dayton, OH, USA; the University of Louisville, Louisville, KY, USA;
Resin Model of Roletto, Italy; Appex GmbH of Augsburg, Germany and Land Rover
Limited, the automotive manufacturer, located in Solihull, England.

    LaserForm ST-100 advantages
    Speed.  Intricate parts and tools can be created in two to three days
using a virtually unattended process.  Thousands of companies are using rapid
prototyping (RP) to produce plastic parts faster than ever before.  LaserForm
ST-100 will bring the same benefits of RP to metal fabricating.
    Cost savings / Cost Avoidance.  The new LaserForm ST-100 material, will
allow companies to go directly from CAD to metal parts in two steps.  Users
can skip the expensive step of creating tools when only a moderate number of
parts are needed, and design changes can be incorporated before committing to
production runs.
    In addition to prototyping, companies with low volume manufacturing
applications, such as those found in the specialty automotive and aerospace
industries, will be able to take full advantage of LaserForm and the benefits
gained from this process.

    Customer comments
    Silvio Favero, founder and owner of Resin Model notes, "The time savings
experienced with this new metal material will allow us to be even more
competitive in our delivery of tools to our customers."
    Ben Staub, President of Bastech, Inc. notes, "LaserForm ST-100 has
significantly improved our processes and applications for creating rapid
tooling.  This is due in part to the surface finish of the new material,
coupled with the oven processing time.  In addition, our machinists say they
like working with LaserForm ST-100."

    Two steps to metal parts
    Using LaserForm ST-100 requires just two steps: 1) creating the stainless
steel part in the Sinterstation system using the SLS process to bond the
LaserForm ST-100 metal powder and 2) using a one-step process to infiltrate
the part with bronze in a kiln-like oven.  The result is a fully dense, fully
functional metal part.
    Creating functional metal prototypes with LaserForm ST-100 takes just two
to three days; more complex tooling inserts for plastic injection molding
takes 5 to 10 days for fabrication and finishing.

    DTM Comments
    "With the introduction of LaserForm ST-100, DTM hopes to capitalize on
some of the inherent advantages of the SLS process, such as the ability to
process metal materials.  DTM's Sinterstation systems have been used primarily
to create plastic parts.  This new material brings the advantages of SLS to
metal fabrication, as well", notes Azucena Overman, Marketing Manager at DTM.
"In addition to LaserForm ST-100, DTM is continuing development efforts of
other metal materials, thus providing SLS users with the broadest range of
metal applications."

    Beta testing goals
    DTM plans to begin a second beta testing phase this fall.  The goals of
this next phase of LaserForm ST-100 beta testing include: 1) expanding its
range of applications, 2) assisting customers with application and process
development, and 3) rounding out the testing phase of a new infiltration oven.

    Commercial availability
    With so many uses for LaserForm ST-100, demand for this new material
throughout the manufacturing world could be brisk.  DTM plans to have
LaserForm ST-100 available to existing DTM customers by the end of August,
giving customers the opportunity to take full advantage of this new metal
part-making capability.