Achieving Surface Finish Requirements on DMLS Parts with Precision Electrochemical Machining

3D Additive Manufacturing is a fast growing technology with metallurgical properties of the “printed” parts achieving manufacturing requirements.  Direct Metal Laser Sintering (DMLS) is one of the few additive manufacturing technologies being used in production.  This technology is used to manufacture direct parts for a variety of industries including aerospace, dental, medical and other industries that have small to medium size, highly complex geometries.  Part tolerance and surface finish are two of the main requirements in addition to metallurgy that must be met by the DMLS parts.  Precision Electrochemical Machining (PECM) is a process capable of achieving these requirements on some applications at a significant cost advantage to other methods.  One example will be described in detail in this paper of an aerospace application requiring a surface finish of 4 Ra micro inch on a complex surface.