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Controlled Porosity Additive Manufacturing

Achieve functional advantages and new design freedoms with with our controlled porosity 3D printing.  Build finished assemblies with solid hardware, gradient structures, and porous features…all in one print.

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Watch our unique method for producing controlled porosity at micron scale for building previously impossible filtration and fluid control assemblies.

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Have a question? Can’t find what you’re looking for? Call us at 860.747.6333, or submit an information request form and someone will get back to you within 48 hours.

Additive Capabilities Specs

Build volume: – 9.7” x 9.7” x 11.0” (L x W x H)

Build materials: – 316L Stainless Steel, Titanium, other alloys consult engineering

Solid feature size resolution: – +/- 0.01”

Porosity range: – 1 to 100+ micron pore size (for custom porosityconsultengineering)

Part-part dimensional consistency: – +/- 0.01”

Solid printed surface finish: – 350 Ra µin

Machined surface finish: – 5 to 32 Ra µin (same as typical hardware)

Build volume:

  • Prototypes: 15.7” W x 11.8” D x 11.8” H (400mm x 300mm x 300mm)
  • Production: 18.0” W x 18.0” D x 32.0” H (457mm x 457mm x 813mm)

Build materials: PEEK, PEKK, PEI, Nylon, ABS, Polyethylene, and more

Porosity range: 100 microns and larger; for custom porosity integration, consult engineering

Pore shape:

  • Lattice: Rectangular, Hexagonal, Triangular
  • Random: Under Development

Solid feature size resolution and dimensional consistency*

  • As Printed: +/- 0.010”
  • Machined: +/- 0.002”

Part density: Up to 100% depending on polymer

Surface finish

  • As printed: 200 to 600 Ra µin
  • Machined: 5 to 32 Ra µin

* Dimensions and tolerances are subject to the polymer chosen and overall part dimensions. Values presented are typical for small parts, <1” (25mm) cross section printed in PEEK with a medium resolution extrusion nozzle. 

 

Consult engineering for unique ceramic options under development

Our Additive Process: A 4 Step Process for Production

  • 1Specifications Review
  • 2Design Iterations & Parameter Optimization
  • 3Printing And Post Processing
  • 4Quality And Validation Testing

The 3D Model

Laser Melts Particles Together

Loose Powder is Removed

Finished Product

Controlled Porosity 3D Printing

Complex Geometries

• Re-think dimensional limitations beyond discs or tubes
• Improve performance by optimizing every aspect of design
• Reduce the overall Bill of Material from many to one

Gradient Structures

• Integrate porous with your hardware like never before
• Achieve multiple micron porosities in a single print
• New capability expansion in areas like Thermal Management

Weight Reduction

• Optimize structure for minimal material & weight
• Achieve up to 90% material reduction in space-saving design
• Eliminate unnecessary Bill of Material components