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Metal 3D Printing: A Case Study of 3D Printed Boots

Metal 3D Printing Art and Design End-use Parts
  • 00003bottonAbigail Tse
  • 00005bottonSep. 13 | 2024
  • 00002botton Metal 3D Printing
  • 00001botton3 Minutes Read
  • 180 clicks

    Selective Laser Melting is the Process

     

    Selective Laser Melting

     

    In our case study, we worked with Bennett Awards to create 3D printed boots using Selective Laser Melting.

     

    Selective Laser Melting, also known as SLM 3D printing, uses a high-powered laser to selectively melt metal powders such as aluminum, titanium, stainless steel or maraging steel layer by layer. SLM 3D printing is able to produce fully dense metal parts with excellent mechanical properties and complex geometries. It is used across a wide range of industries to create durable, lightweight, high-strength parts.

     

    Metal 3D Printing Capabilities (Based on this case study.)

     

    Items

    Process

    Material

    Price

    Quantities

    Lead Time

    Tolerance

    Life-size Boots

    Selective Laser Melting

    Aluminum 6061

    $$

    20 Pieces

    5 Days

    ±0.3%mm

     

    3d printed boot

     

    Mechanical Properties of 3D Printed Aluminum 6061

     

    Hardness

    Density

    Tensile Strength

    Elongation at Break

    Yield Strength

    95 HB

    2.8 g/cm³

    290MPa

    10%

    240MPa

     

    The Metal 3D Printing Process to Make Those Boots

     

    Step 1: Printability check.

    Step 2: Import the STL file on the metal 3D printers.

    Step 3: Arrange and optimize build chamber space.

    Step 4: Metal 3D printers operating: aluminum 6061 powder bed preparation, laser scanning and melting, solidification and bonding, solid part is built.

    Step 5: Cool down the metal 3D printed boots.

    Step 6: Take the boots out of the build chamber.

    Step 7: Clean residue aluminum powders.

    Step 8: Send the boots to heat treatment.

    Step 9: Quality inspection.

    Part 10: Parts that fail quality inspection are sent for rework.

    Step 11: Quality inspection again.

    Step 12: Packing and shipping.

     

    3d printed shoe

     

    Selective Laser Melting Materials at 3DSPRO

     

    Aluminum

    Stainless Steel

    Titanium

    Maraging Steel

    AlSi10Mg

    316L

    Ti₆Al₄V

    18Ni300

    6061

    17-4 PH

    /

    /

     

    Take A Closer Look

     

    Customer Feedback

     

    “The biggest problem we faced in this case was managing the timeline. Many of our customers are unaware of how long these processes take, which sometimes puts us in a tight spot with unrealistic deadlines. This was a major factor in deciding our approach. Fortunately, you confirmed the production timeline, and here we are.”

     

    “I honestly don’t think there is anything we can't build and that is a crazy powerful feeling for a designer. Partnering with companies like yours that give us the confidence to think that I can pull off some of this crazy stuff, so thank you.”

     

    Life-size 3D Printed Boots

     

    This life-size 3D printed boot was created to the measurements of Mexican defender Edson Alvarez’s shoes. The project demonstrates the capability of metal 3D printing and the potential to create highly customized and durable footwear that can be tailored to the exact measurements and requirements of the wearer.

     

    The boot’s design and sturdy construction showcase the precision and strength that can be achieved with metal 3D printing, highlighting the versatility of metal 3D printing for producing highly durable and customized items.

     

    3d printed boot

     

    The Structure

     

    The Shape

     

    SLM 3D printing can produce parts with intricate geometries. This boot features a streamlined design similar to cleats, though it is less complex than honeycomb or lattice structures. SLM 3D printing can easily create this boot with a quick turnaround time.

     

    slm 3d printing_aluminum

     

    The Upper

     

    The upper of the metal 3D printed boot is flat with rounded edges. This is a significant advantage of SLM 3D printing over CNC machining because SLM can directly create smooth and rounded corners without additional processing.

     

    3d printed shoe

     

    Counter

     

    By following the design guidelines, metal 3D printing can successfully produce relief and engraved details. For example, the word "Modelo" is engraved on both the left and right sides of the counter. In addition, there are three engraved horizontal lines surrounding the counter. (If you are unsure of the design guidelines, we can assess printability for you.)

     

    3d printed boot_metal 3d printing

     

    metal 3d printed boot

     

    metal 3d printing_boot

     

    Internal

     

    Another major advantage of SLM 3D printing is its ability to print objects in one piece, even with hollow structures (if the escape hole is sufficiently large). This capability is demonstrated in the internal structure of the metal printed boot. Interestingly, our client plans to pour ‘Modelo Beer’ into the boot! (Honestly, the only time I’ve seen someone drink from a boot was when Daniel Ricciardo did a ‘Shoey’ after winning a Formula 1 race.)

     

    3d printing metal part

     

    Outsole

     

    The outsole of the boot features embossed details, including the spikes and fonts, all of which have been printed successfully and clearly. The shapes of the spikes are also printed with high accuracy, as can be seen in the following photo.

     

    3d printed shoe outsole

     

    The Surface Finish

     

    SLM 3D printed parts have a smooth, slightly shiny, but grainy surface finish. The original color is metallic gray, and the surface feels a bit powdery due to the nature of the powder bed fusion process. However, we remove any residual powder as thoroughly as possible.

     

    metal 3d printing_surface finish

     

    selective laser melting_sruface finish

     

    More Details

     

    selective laser melting_application

     

    selective laser melting

     

     

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