Direct Metal Printing Rapidly Delivers Innovative Faucet

Kallista, a division of Kohler, has developed a new faucet with a geometric shape. Inspired by the outline of a cube, the Grid faucet features right angles and integrated water channels, a design that could not be easily manufactured using traditional manufacturing methods.

To produce this faucet, designers turned to 3^rd Dimension, a manufacturer located in Indianapolis, Indiana, that offers metal 3D printing as well as machining, milling and finishing. 3^rd Dimension designed support structures to strengthen the design during printing, and manufactured the Grid faucets using a ProX 320 Direct Metal Printing (DMP) system from 3D Systems. DMP is 3D Systems’ name for its metal powder-bed 3D printing process, and the company says its system offers precision down to about 50 microns. The faucets were printed with the company's LaserForm 316L stainless steel powder .

The parts were removed from the build plate with EDM, then heat-treated to reduce stresses. Machining added threads for the mating connectors and aerator. After a tumble deburring process to create a uniform surface finish, the faucets were powder-coated to achieve a black matte finish.

3D printing these parts not only enabled a difficult-to-manufacture design, but also sped the development of the product. The faucets were printed within hours, and fully finished within a couple of weeks.