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Copper 3D Printing Complete Guide

Copper is one of the newest and most promising areas of metal 3D printing for everything from electric motors to heat sinks.

Previously, copper 3D printing was a challenge due to the metal's reflectivity and high thermal conductivity, but advances in printers and materials have largely resolved these early problems. Today, 3D printed copper propulsion systems send rockets into space, 3D printed copper heatsinks cool processors, and 3D printed copper coils boost the performance of electric motors.

3D printed copper parts (Source: Trumpf)

Why 3D print copper?

Copper has always been a very useful metal due to its ability to conduct heat and electricity, resist corrosion and even kill bacteria and viruses. Demand for complex copper parts is on the rise as 3D printing opens up even more uses and possibilities for this metal.

3D printing (also known as additive manufacturing) allows the creation of exceptionally complex shapes, fine details, internal structures and lattice inserts that are not possible with any other form of metal fabrication. These capabilities reduce weight, increase efficiency, and reduce fabrication and assembly times, as multi-component assemblies can be 3D printed as a single unit.

Additive Metallurgy

3D printing also allows this relatively expensive metal to be produced more efficiently, reducing waste by using only the amount of material needed to make each part. For companies interested in copper 3D printing, reducing raw material costs is critical.

If you already produce custom copper parts, 3D printing can significantly reduce your production costs while optimizing part performance.

Markforged 3D printed copper heatsink (Source: Markforged)

Although there aren't many 3D printers that can print copper, there is still a wide variety of printing technologies and prices.

FDM printers using copper-filled plastic filament can produce copper jewelry, decorative items, and other parts that are almost 100% copper. While for more advanced production, 3D printers using copper powder, rods or copper polymer slurry produce industrial parts with excellent mechanical and conductive properties, which can meet international standards such as IACS (International Annealed Copper Standard).

Let's look at what types of printers can work with copper today. Trumpf TruPrint 1000 Green Edition 3D Printer several equipment manufacturers have recently included copper in their material list. Since copper is highly reflective, laser processing of the powder has been a hurdle for manufacturers. However, this technology and materials have evolved to solve this problem.

3D printer manufacturer Trumpf, for example, has developed an industrial green laser that can 3D print materials such as copper, copper alloys, and precious metals that are difficult to process with infrared waves.

Two powder layer technologies for metal 3D printing, DMLS (Direct Metal Laser Sintering) and EBM (Electron Beam Melting), work by depositing a thin layer of copper powder onto a platform inside the printer. The powder heats up while lasers or electron beams draw the first layer of the part. When the particles in the layer fuse, the platform is lowered slightly into the assembly chamber, and fresh powder is poured on top, and the process is repeated. Some of the copper powder left over from the process can be recycled for use in the next print.

Copper additive manufacturing powder from GNK Powder Metallurgy (Source: GNK)

Copper-bonded 3D inkjet printers

Copper powder bonded with a liquid binder and sintered in a furnace is a 3D printing technique known as binder inkjet printing that allows parts to be obtained without the use of an auxiliary material. Bond jetting is a no-heat process in which a bonding layer is sprayed between each layer of metal; the binder is then removed during the sintering process.

Binder blasting is a popular additive manufacturing method for high volume metal parts.

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