3D metal printing ireland

FAQ's

How much does your 3D printing service cost?

The cost of your 3D printed parts depends on factors such as part volume, part complexity, choice of material, which 3D printing technology is used, and if any post processing is required. For more details on these cost factors, see our article on the cost of 3d printing. To check the cost of your 3D printed part, simply upload a CAD (.STL) file and select your material and 3D printing technology to receive a quote within seconds.

How do you guarantee the quality of my prints?

Your parts are made by experienced 3D printing shops within our network. All facilities are regularly audited to ensure they consistently meet the Hubs quality standard. We include a standardized inspection report with every order and offer a First Article Inspection service on orders of 100+ units.

We have partners in our network with the following certifications, available on request: ISO9001, ISO13485 and AS9100.
Follow this link to read more about our quality assurance measures.

How do I select the right 3D printing process for my prints?

You can select the right 3D printing process by examining which materials suit your need and what your use case is.

By material: if you already know which material you would like to use, selecting a 3D printing process is relatively easy, as many materials are technology specific.
By use case: once you know whether you need a functional or visual part, choosing a process is easy.

For more help, read our guide to selecting the right 3D printing process. Find out more about Fused Deposition Modeling (FDM), Selective Laser Sintering (SLS), Multi Jet Fusion (MJF) and Stereolithography (SLA).

How can I reduce the cost of my 3D prints?

In order to reduce the cost of your 3D prints you need to understand the impact certain factors have on cost. The main cost influencing factors are the material type, individual part volume, printing technology and post-processing requirements.

Once these have been decided, an easy way to further cut costs is to reduce the amount of material used. This can be done by decreasing the size of your model, hollowing it out, and eliminating the need for support structures.

To learn more, read our full guide on how to reduce the cost of 3D printing.

Where can I learn more about 3D printing?

Our knowledge base is full of in-depth design guidelines, explanations on process and surface finishes, and information on how to create and use CAD files. Our 3D printing content has been written by an expert team of engineers and technicians over the years.

See our complete engineering guide to 3D printing for a full breakdown of the different 3D printing technologies and materials. If you want even more 3D printing, then check out our acclaimed 3D printing handbook here.

We have an extensive range of online resources developed to help engineers improve their capabilities.

Introductory guides

Design guides

Material guides

Applications

CAD & file preparation

Post processing & finishing

Our other manufacturing capabilities

CNC machining

CNC machining

Milling (3-, 4- & full 5-axis), turning and post-processing

• 50+ metals and plastics & 10 surface finishes


• Tolerances down to ±.0008” (0.020 mm)

• Lead times from 5 business days

See our CNC machining services

Put your 3D printed parts into production today

Get an instant 3D printing quote

first complete metal 3D printing system for office or design office

In October 2021, Raise3D announced the release of the MetalFuse metal 3D printing system as the best solution for small batch production of complex metal products. In February 2022, the Russian distributor of the company, Tsvetnoy Mir, brought the system to Russia and is ready to share detailed information about it.

MetalFuse is a turnkey complex consisting of three pieces of equipment for 3D printing, cleaning and sintering of polymer-metal blanks into solid metal products.

From left to right, the components of the complex are shown:

1. Forge 1 desktop 3D printer with metal-filled filament.
2. Station D200-E for catalytic debinding of resin.
3. Furnace S200-C for vacuum sintering of workpieces into all-metal products.

The first stage of fabrication on MetalFuse is the actual printing of the necessary part on the Forge 1 3D printer. The printer is quite easy to use and similar to other FDM/FFF 3D printers. However, it has significant differences. It has two extruders specially designed for metal-filled filament printing, an optimized hot end and extrusion system, automatic first layer control and accurate calibration. Forge 1 prints BASF Ultrafuse 316L and Ultrafuse 17-4 PH metal-filled filament with a diameter of 2.85 mm. The thread consists of particles of pure metal (steel) and a binder polymer.

in the photo: 3D printer Forge 1

Characteristics of the 3D printer Forge 1:

Printer size: 620 × 626 × 760 mm

Building area: 300 × 300 × 300 mm 9000 mm 9000

Technology Technology Technology Technology press: FFF

Extruder: 2 extruders with electronic lifting system

XYZ positioning accuracy: 0.78125, 0.78125, 0.078125 microns

Print head speed: 30-150 mm/s

Max. platform heating temperature: 120 ºC

Materials supported: Ultrafuse 316L, Ultrafuse17-4 PH

Head diameter: 2.85 mm (Direct feed)

Max. extruder temperature: 300℃

Software: ideaMaker metal

Supported file types: STL, OBJ, 3MF, OLTP

OS: Windows/ macOS/ Linux

Pictured: Printing on Forge 1

Next device - station D200-E designed to remove the binder polymer . The D200-E uses a catalytic oxalic acid cleaning process. The process is safe and environmentally friendly. Cleaning with oxalic acid is easier than nitric acid treatment and faster than solvent and thermal treatment. It can even be used for titanium and copper.

When comparing the catalytic cleaning method with the solvent extraction method, one can see the clear advantages of the first: the cleaning cycle takes much less time (4-12 hours versus 12-72), the layer height is not limited, the residual rate of the polymer is lower. The second method leads to swelling and cracking, while there are no such defects after catalytic purification.

The use of a catalyst can reduce time costs by 60% and at the same time obtain products with a density of up to 97% of the level of wrought iron, increasing strength by 52% compared to products obtained by removing the binder with solvents.

D200-E features:

Station size: 806×806×1545 mm

Working load area: 200×200×200 mm

Tray Type: Adjustable Tier Tray (6 Tier)

Type of shielding gas: argon or nitrogen

Maximum volume of catalyst in the storage tank: 2 liters

Maximum gas flow: 5 l/min

Maximum cleaning speed: 1. 55 mm/h

Power: 220-230 VAC, 50Hz, single phase, 16 A/3.5 kW

Exhaust gas treatment: activated carbon adsorption unit

In the photo: the process of installing the model in the D200-E

The third device of the complex - furnace S200-C for vacuum sintering of blanks into all-metal products .

In the photo: the process of loading products into the S200-C sintering oven

Features of the S200-C oven:

Furnace size: 1304×1058×1950 mm

Working area: 200×200×200 mm

Sintering time: approx. 20 hours

Tray Type: Adjustable Tier Tray (6 Tier)

Type of shielding gas: argon or nitrogen

Maximum heat load: 12.5 kW

Maximum operating temperature: 1450℃

Power input: 380-400 VAC, 50Hz, three-phase, 40A/27kW

Pre-emergency stop: yes

Overheat protection: 1500℃

The S200-C oven from Raise3D uses vacuum sintering, does not require consumables, its cycle is 2 times shorter than other furnaces (10-24 hours compared to 17-31), it has a low gas consumption.

As already mentioned, Forge 1 prints with metal-filled plastic BASF Ultrafuse 316L and Ultrafuse 17-4 PH . These are innovative materials for the production of metal parts, developed by the largest German chemical concern BASF. The thread consists of 80-90% stainless steel and 10-20% polymer. The polymer contained in these materials acts as a link. Parts printed with Ultrafuse acquire their final properties, including hardness and strength, through a process of catalytic debinding and sintering.

The picture above shows what an Ultrafuse part looks like at each stage of production. After printing, it consists of metal and plastic and has a greenish tint. The model is still fragile and requires careful handling. Further, after cleaning from the polymer in D-200-E, it acquires a brown tint and consists of particles of pure metal and residual binder. Finally, after sintering at high temperatures, the secondary binder is removed, the metal particles are fused, and we get the part of the metallic color we are used to. The model reaches its final strength and hardness properties. Then it can be polished, processed in other familiar ways, or left as is.

In the photo: from left to right the product after printing on the printer, the product after cleaning and sintering, the product after polishing.

Photo: models made with MetalFuse

The table below compares the properties of MIM and MetalFuse parts:

From the software for this system Raise3D introduced a new slicer - ideaMaker Metal . It has built-in templates for metal printing, it takes into account catalytic cleaning and sintering, supports mixed-type models (printing with multiple nozzles, with multiple templates, different layer thicknesses). ideaMaker is ultra-fast 64-bit and works with large models. Also, owners of the Forge 1 printer can use the web platform RaiseCloud , with which you can remotely control the print command. It monitors and reports on all printing processes.

The whole complex is environmentally friendly. The equipment is equipped with filters that remove harmful substances and reduce environmental pollution.

Pictured: filters installed in MetlaFuse

MetalFuse enables easy, fast, safe, economical and environmentally friendly in-house production of high quality metal parts in small batches. Savings in comparison with printing by selective laser sintering is 1.4-2 times. The equipment is much cheaper than laser systems. According to the manufacturer, if you need to produce a small or medium batch of complex metal products, MetalFuse is the best solution on the market.

Detailed information about the MetalFuse system.

Our contacts: T: 8 (800) 550-02-09 | | www.cvetmir3d.ru

Our VKontakte group: https://vk. com/cvetmir3d

Our Youtube channel: https://www.youtube.com/channel/UCnfeyFh4TKIVpMCMi1zd0fA

Our channel "3D Printing Life Hacks ": https://www.youtube.com/channel/UCUv3Lk-oDMh38rKX68kUBYg

Our Telegram channel: https://t.me/cvetnoymir3d

Our Telegram channel with 3D printing tips https://t .me/cvetmir3d

We are on Facebook: https://www.facebook.com/groups/cvetmir3d/

We are on Instagram: https://www.instagram.com/cvetmir3d/

Metal 3D printing

Metal 3D printing can be considered one of the most enticing and technologically challenging areas of additive manufacturing. Attempts to print with metals have been made since the early days of 3D printing technologies, but in most cases they ran into technological incompatibilities. In this section, we will look at technologies that have been tested for printing both composite materials containing metals and pure metals and alloys.

• 1 3D inkjet printing (3DP)
• 2 Lamination Printing (LOM)
• 3 Layered welding (FDM/FFF)
• 4 Selective Laser Sintering (SLS) and Direct Metal Sintering (DMLS)
• 5 Selective Laser (SLM) and Electron Beam Melting (EBM)
• 6 Direct laser additive construction (CLAD)
• 7 Free electron beam melting (EBFȝ)

3D inkjet printing (3DP)

How 3D inkjet printers (3DP) work

Inkjet 3D printing is not only one of the oldest additive manufacturing techniques, but also one of the most successful in terms of using metals as consumables . However, it is necessary to immediately clarify that this technology allows you to create only composite models due to the technological features of the process. In fact, this method allows you to create three-dimensional models from any materials that can be processed into powder. The binding of the powder is carried out using polymers. Thus, finished models cannot be called fully "metal".

At the same time, there is the possibility of converting composite models into all-metal ones due to heat treatment in order to melt or burn out the binder material and sinter metal particles. The models obtained in this way do not have high strength due to porosity. An increase in strength is possible due to the impregnation of the resulting all-metal model. For example, it is possible to impregnate a steel model with bronze to obtain a stronger structure.

Models obtained in this way, even with metal impregnation, are not used as mechanical components due to their relatively low strength, but are actively used in the jewelry and souvenir industry.

Lamination printing (LOM)

How 3D printers using lamination technology (LOM) work

models.

Metallic foil can also be used as a consumable.

The resulting models are not all metal, as their integrity is based on the adhesive used to bond the consumable sheets.

The advantage of this technology is the relative cheapness of production and the high visual similarity of the resulting models with all-metal products. Typically, this method is used for layout.

FDM/FFF

Model made of BronzeFill before and after polishing

The most popular 3D printing method has also not bypassed the use of metals as consumables. Unfortunately, attempts to print with pure metals and alloys have so far not led to significant success. The use of refractory metals runs into quite predictable problems with the choice of materials for the construction of extruders, which, by definition, must withstand even higher temperatures.

Printing with fusible alloys (for example, tin) is possible, but does not give enough high-quality output for practical use.

Thus, in recent years, the attention of consumables developers has switched to composite materials, similar to inkjet printing. A typical example is BronzeFill, a composite material consisting of thermoplastic (details not disclosed, but apparently PLA plastic is used) and bronze powder. The resulting models have a high visual similarity with natural bronze and can even be polished to a high gloss. Unfortunately, the physical and chemical properties of finished products are limited by the parameters of the thermoplastic binder, which does not allow classifying such models as all-metal.

Nevertheless, such materials can be used not only in the creation of models, souvenirs and art objects, but also in industry. Thus, the experiments of enthusiasts have shown the possibility of creating conductors and shielding materials using thermoplastics with a metal filler. The development of this direction can make it possible to print electronic circuit boards.

Selective laser sintering (SLS) and direct metal sintering (DMLS)

The most common method for creating all-metal 3D models involves the use of laser machines for sintering metal powder particles. This technology is referred to as Selective Laser Sintering or SLS. It should be noted that SLS is used not only for working with metals, but also with thermoplastics in powder form. In addition, metallic materials are often coated with more fusible materials to reduce the required power of laser emitters. In such cases, finished metal models require additional sintering in furnaces and impregnation to increase strength.

A variation of the SLS technology is Direct Metal Laser Sintering (DMLS), which, as the name implies, is focused on working with pure metal powders. These plants are often equipped with sealed working chambers filled with an inert gas for working with metals subject to oxidation, such as titanium. In addition, DMLS printers necessarily apply consumable heating to a point just below the melting point, which saves on the power of laser systems and speeds up the printing process.

SLS, DLMS and SLM systems

The laser sintering process begins with the application of a thin layer of heated powder onto the work platform. The thickness of the applied layers corresponds to the thickness of one layer of the digital model. Then the particles are sintered between themselves and with the previous layer. Changing the trajectory of the laser beam is carried out using an electromechanical system of mirrors.

After a layer is drawn, the excess material is not removed, but serves as a support for subsequent layers, which allows you to create complex-shaped models, including hinged elements, without the need to build additional support structures. This approach, coupled with high precision and resolution, makes it possible to obtain parts that require almost no machining, as well as solid parts of a level of geometric complexity that is unattainable by traditional production methods, including casting.

Laser sintering allows you to work with a wide range of metals, including steel, titanium, nickel alloys, precious materials, etc. The only drawback of the technology can be considered the porosity of the resulting models, which limits the mechanical properties and does not allow achieving strength at the level of cast counterparts.

Selective Laser (SLM) and Electron Beam Melting (EBM)

Despite the high quality of the patterns produced by laser sintering, their practical application is limited by the relatively low strength due to porosity. Such products can be used for rapid prototyping, prototyping, jewelry production and many other tasks, but are of little use for the production of parts that can withstand high loads. One solution to this problem has been the conversion of direct metal laser sintering (DMLS) technology to laser melting additive manufacturing (SLM) technology. In fact, the only fundamental difference between these methods is the degree of heat treatment of the metal powder: SLM technology is based on complete melting to obtain homogeneous models that are practically indistinguishable in physical and mechanical properties from cast counterparts.

An example of a titanium implant made using Electron Beam Melting (EBM) technology

Electron Beam Melting (EBM) has become a parallel method with excellent results. At the moment, there is only one manufacturer that creates EBM printers - the Swedish company Arcam.

EBM achieves precision and resolution comparable to laser melting, but with some advantages. Thus, the use of electron guns makes it possible to get rid of the delicate electromechanical mirror systems used in laser systems. In addition, the manipulation of electron beams using electromagnetic fields is possible at speeds that are incomparably higher compared to electromechanical systems, which, coupled with an increase in power, makes it possible to achieve increased productivity without significantly complicating the design. Otherwise, the design of SLM and EBM printers is similar to laser metal sintering machines.

Ability to work with a wide range of metals and alloys allows you to create small batches of specialized metal parts that are almost as good as samples obtained using traditional production methods. There is no need to create additional tools and infrastructure, such as molds and furnaces. Accordingly, significant savings are possible in prototyping or small-scale production.

Laser and electron beam melting machines have been successfully used to produce items such as orthopedic titanium prostheses, gas turbine blades and jet engine injectors, among others.

Direct Laser Additive Building (CLAD)

How CLAD plants work

Not so much a 3D printing technology as a "3D repair" technology. The technology is used exclusively at the industrial level due to the complexity and relatively narrow specialization.

CLAD is based on the deposition of metal powder on damaged parts with immediate laser welding. The positioning of the "print head" is carried out along five axes: in addition to moving in three planes, the head has the ability to change the angle of inclination and rotate around the vertical axis, which allows you to work at any angle.

Such devices are often used to repair large items, including manufacturing defects.

Learn more

• 
  3D printing furniture design
• 
  Best 3d printer abs filament
• 
  How to make money with a 3d printer reddit
• 
  Closed loop 3d printer
• 
  Dynamism 3d printing
• 
  Orthodontic 3d printer
• 
  3D printing sports equipment
• 
  3D printing keychain
• 
  Toughest 3d printing material
• 
  Why 3d printing is overhyped
• 
  3D printer world