The purpose of this study was to find and optimize the process parameters of producing tool steel 1.2709 at a layer thickness of 100 μm by DMLS (Direct Metal Laser Sintering). HPDC (High Pressure Die Casting) tools are printed from this material. To date, only layer thicknesses of 20-50 μm are used, and parameters for 100 µm were an undescribed area, according to the state of the art. Increasing the layer thickness could lead to time reduction and higher economic efficiency. The study methodology was divided into several steps. The first step was the research of the single-track 3D printing parameters for the subsequent development of a more accurate description of process parameters. Then, in the second step, volume samples were produced in two campaigns, whose porosity was evaluated by metallographic and CT (computed tomography) analysis. The main requirement for the process parameters was a relative density of the printed material of at least 99.9%, which was achieved and confirmed using the parameters for the production of the samples for the tensile test. Therefore, the results of this article could serve as a methodological procedure for optimizing the parameters to streamline the 3D printing process, and the developed parameters may be used for the productive and quality 3D printing of 1.2709 tool steel.
Keywords: 3D printing; 3D printing parameters optimization; Direct Metal Laser Sintering (DMLS); additive manufacturing; energy density; layer thickness.