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Eiger is an integrated, connected platform designed to take you from CAD to functional part quickly. The browser-based 3D printing software workflows are secure, fast, and intuitive.

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Eiger, our 3D printing software, enables you to slice and print composite parts reinforced with continuous fibers and metals. You can prep parts for printing with a single click, or drill deeply into part settings to optimize your final product.

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Incorporating 3D printing into tooling and end use applications requires total confidence in part strength. Traditionally, this required lengthy design-print-break testing cycles or costly analysis software. Simulation takes the guesswork out of 3D printing by integrating virtual testing and time/cost optimization into our familiar slice and print workflow.

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Learn the basics of 3D printing software in From Art to Part: A Step-by-Step Guide to 3D Printing

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Metal 3D Printing Service for Custom Parts

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→ Capabilities
→ Available Alloys
→ Compare Material Properties
→ Surface Finishes
→ Post-Processing
→ Why Metal 3D Printing?

Direct metal laser sintering (DMLS) is an industrial metal 3D printing process that builds fully functional metal prototypes and production parts in 7 days or less. A range of metals produce final parts that can be used for end-use applications.

Metal 3D printing technology is commonly used for:

  • Prototyping in production-grade materials
  • Complex geometries
  • Functional, end-use parts
  • Reducing metal components in an assembly

We hope you find this guide helpful. If the file did not download, you can find it here.

Metal 3D Printing Guide

Jump start your metal 3D printing with this guide that covers material selection, design, post-processing, and quality inspections. 

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Metal 3D Printing Capabilities

Our basic guidelines for metal 3D printing include important design considerations to help improve part manufacturability, enhance cosmetic appearance, and reduce overall production time.

Metal 3D Printing Tolerances

For well-designed parts, tolerances of +0.003 in. (0.076mm) plus 0.1% of nominal length can typically be achieved. Note that tolerances may change depending on part geometry.

Max Dimensions

Layer Thickness

Minimum Feature Size

Tolerances

*At this time, Inconel 718 and Aluminum are the only materials available on our large format, X Line machine


Metal 3D Printing Material Options

Below is our available metal alloys for 3D printing. Various heat treatments are available depending on material.

Stainless Steel (17-4 PH)

Stainless Steel 17-4 PH is a precipitation hardened stainless steel that is known for its hardness and corrosion resistance. If needing a stainless steel option, select 17-4 PH for its significantly higher tensile strength and yield strength, but recognize that it has far less elongation at break than 316L. Final parts built 17-4 PH receive vacuum solution heat treatment as well as H900 aging.

Primary Benefits

  • Heat treated for full hardness and strength
  • Corrosion resistance


LEARN MORE>

Stainless Steel (316L)

Stainless steel 316L is a workhorse material used for manufacturing acid and corrosion resistant parts. Select 316L when stainless steel flexibility is needed; 316L is a more malleable material compared to 17-4 PH. Final parts built in 316L receive stress relief application.

Primary Benefits

  • Acid and corrosion resistance
  • High ductility

LEARN MORE>

Aluminum (AlSi10Mg)

Aluminum (AlSi10Mg) is comparable to a 3000 series alloy that is used in casting and die casting processes. It has good strength -to-weight ratio, high temperature and corrosion resistance, and good fatigue, creep and rupture strength. AlSi10Mg also exhibits thermal and electrical conductivity properties. Final parts built in AlSi10Mg receive stress relief application.

Primary Benefits

  • High stiffness and strength relative to weight
  • Thermal and electrical conductivity


LEARN MORE>

Inconel 718

Inconel is a high strength, corrosion resistant nickel chromium superalloy ideal for parts that will experience extreme temperatures and mechanical loading. Final parts built in Inconel 718 receive stress relief application. Solution and aging per AMS 5663 is also available to increase tensile strength and hardness.

Primary Benefits

  • Oxidation and corrosion resistance
  • High performance tensile, fatigue, creep, and rupture strength


LEARN MORE>

Cobalt Chrome (Co28Cr6Mo)

Cobalt Chrome (Co28Cr6Mo)​ is a superalloy is known for its high strength-to-weight ratio.

Primary Benefits​

  • High performance tensile and creep
  • Corrosion resistance


LEARN MORE>

Titanium (Ti6Al4V)

Titanium (Ti6Al4V) is a workhorse alloy. Versus Ti grade 23 annealed, the mechanical properties of Ti6Al4V are comparable to wrought titanium for tensile strength, elongation, and hardness. Final parts built in Ti6Al4V receive vacuum stress relief application.

Primary Benefits​

  • High stiffness and strength relative to weight
  • High temperature and corrosion resistance


LEARN MORE>

Compare Material Properties

20 μm = high resolution (HR)
30, 40, and 60 μm = normal resolution (NR)

  • US
  • Metric

Materials Resolution Condition Ultimate Tensile Strength
(ksi)		 Yield Stress
(ksi)		 Elongation 
(%)		 Hardness
Stainless Steel
(17-4 PH)		 20 μm Solution & Aged (H900) 199 178 10 42 HRC
30 μm Solution & Aged (H900) 198 179 13 42 HRC
Stainless Steel
(316L)		 20 μm Stress Relieved 82 56 78 90 HRB
30 μm Stress Relieved 85 55 75 88 HRB
Aluminum
(AlSi10Mg) 		 20 μm Stress Relieved 39 26 15 42 HRB
30 μm Stress Relieved 50 33 8 59 HRB
40 μm Stress Relieved 43 27 10 50 HRB
Cobalt Chrome
(Co28Cr6Mo)		 20 μm As Built 182 112 17 39 HRC
30 μm As Built 176 119 14 38 HRC
Inconel 718 20 μm Stress Relieved 143 98 36 33 HRC
30 μm Stress Relieved 144 91 39 30 HRC
30 μm Solution & Aged per AMS 5663 208 175 18 46 HRC
60 μm Stress Relieved 139 83 40 27 HRC
60 μm Solution & Aged per AMS 5663 201 174 19 45 HRC
Titanium
(Ti6Al4V)		 20 μm Stress Relieved 153 138 15 35 HRC
30 μm Stress Relieved 144 124 18 33 HRC

Materials Resolution Condition Ultimate Tensile Strength
(MPa)		 Yield Stress
(MPa)		 Elongation
(%)		 Hardness
Stainless Steel
(17-4 PH)		 20 μm Solution & Aged (H900) 1,372 1,227 10 42 HRC
30 μm Solution & Aged (H900) 1,365 1,234 13 42 HRC
Stainless Steel
(316L)		 20 μm Stress Relieved 565 386 78 90 HRB
30 μm Stress Relieved 586 379 75 88 HRB
Aluminum
(AlSi10Mg) 		 20 μm Stress Relieved 268 180 15 46 HRB
30 μm Stress Relieved 345 228 8 59 HRB
40 μm Stress Relieved 296 186 10 50 HRB
Cobalt Chrome
(Co28Cr6Mo)		 20 μm As Built 1255 772 17 39 HRC
30 μm As Built 1213 820 14 38 HRC
Copper
(CuNi2SiCr)		 20 μm Precipitation Hardened 496 434 23 87 HRB
Inconel 718 20 μm Stress Relieved 986 676 36 33 HRC
30 μm Stress Relieved 993 627 39 30 HRC
30 μm Solution & Aged per AMS 5663 1434 1207 18 46 HRC
60 μm Stress Relieved 958 572 40 27 HRC
60 μm Solution & Aged per AMS 5663 1386 1200 19 45 HRC
Titanium
(Ti6Al4V)		 20 μm Stress Relieved 1055 951 15 35 HRC
30 μm Stress Relieved 993 855 18 33 HRC

These figures are approximate and dependent on a number of factors, including but not limited to, machine and process parameters. The information provided is therefore not binding and not deemed to be certified. When performance is critical, also consider independent lab testing of additive materials or final parts.

Surface Finish Options


Standard Finish

Expect roughness values of 200 to 400 µin Ra (0.005 to 0.010mm Ra), depending on material and resolution. Support structures are removed and layer lines are visible.


Custom Finish

We offer brushed surfaces in a range of grits and polished mirror finishes. Be sure to indicate if the custom surface finish is for functional or aesthetic purposes so we can best consult you on our custom options.

Post-Processing Capabilities for Metal 3D-Printed Parts

Improve strength, dimensional accuracy, and cosmetic appearance of final metal components with DMLS for production.

Surface Finishing

  • 3- and 5-axis milling
  • Turning
  • Polish (Mirror or Brushed)
  • Passivation
  • Wire EDM
  • Tapping and reaming

Heat Treatments

  • Stress relief
  • NADCAP heat treatment
  • Hot isostatic pressing (HIP)
  • Solution annealing
  • Aging

Mechanical Testing

  • Tensile
  • Rockwell Hardness

Powder Analysis & Material

  • Traceability
  • Chemistry
  • Particle size and distribution analysis

Why Use Metal 3D Printing?

See how metal additive manufacturing technology can be used to reduce components within an assembly, fabricate complex geometries, and ultimately save you time and costs.

Click to enlarge

How Does Metal 3D Printing Work?

The DMLS machine begins sintering each layer—first the support structures to the base plate, then the part itself—with a laser aimed onto a bed of metallic powder. After a cross-section layer of powder is micro-welded, the build platform shifts down and a recoater blade moves across the platform to deposit the next layer of powder into an inert build chamber. The process is repeated layer by layer until the build is complete.

When the build finishes, an initial brushing is manually administered to parts to remove a majority of loose powder, followed by the appropriate heat-treat cycle while still fixtured in the support systems to relieve any stresses. Parts are removed from the platform and support structures are removed from the parts, then finished with any needed bead blasting and deburring. Final DMLS parts are near 100 percent dense.

Large Format Metal 3D Printing

We recently added the GE Additive X Line to our fleet of metal 3D printers to build large Inconel 718 and Aluminum (AlSi10Mg) parts. Have a project that might be a good fit? Contact us and we can discuss your requirements.

Learn More >

Metal 3D Printing for Production

Improve strength, dimensional accuracy, and cosmetic appearance for end-use metal components with post-processing options like CNC machining and heat treatments.

Learn More >

Resources

Post-Processing for Metal 3D Printing

Learn how to improve dimensional accuracy, surface roughness, and mechanical properties on metal parts with high-requirement applications.

Read Design Tip

Combining Part Assemblies with Additive Manufacturing to Reduce Cost and Increase Performance

How to find the right opportunities to consolidate multi-part assemblies into single components with industrial 3D printing

Read White Paper

Inconel 718: A Workhorse Material for Additive Manufacturing

Inconel 718 is a go-to material for additive manufacturing of metal parts.

Read Blog

Large Format 3D Printing for Aluminum and Inconel Parts

When you’re printing really large parts in metal, it’s great to have a choice of materials. Aluminum and Inconel 718 both make a lot of sense, but which one is the best for your application?

Read Blog

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How metal 3D printers work. Overview of SLM and DMLS technologies. additive manufacturing. 3D metal printing.


Metal 3D printing. Additive technologies.

SLM or DMLS: what's the difference?

Hello everyone, Friends! 3DTool is with you!

BLT metal 3D printer catalog

Selective laser melting ( SLM ) and direct metal laser sintering ( DMLS ) are two additive manufacturing processes that belong to the family of 3D printing using the powder layer method. The two technologies have much in common: they both use a laser to selectively melt (or melt) metal powder particles, bonding them together and creating a pattern layer by layer. In addition, the materials used in both processes are metals in granular form.

The differences between SLM and DMLS come down to the basics of the particle bonding process: SLM uses metal powders with a single melting point and completely melts the particles, while in DMLS the powder consists of materials with variable melting points.


Specifically:
SLM produces single metal parts while DMLS produces metal alloy parts.
Both SLM and DMLS technologies are used in industry to create final engineering products. In this article, we will use the term "metal 3D printing" to summarize the 2 technologies. We will also describe the main mechanisms of the manufacturing process that are necessary for engineers to understand the advantages and disadvantages of these technologies.
There are other manufacturing processes for producing dense metal parts, such as electron beam melting (EBM) and ultrasonic additive manufacturing (UAM). Their availability and distribution is rather limited, so they will not be presented in this article.

How 3D printing with SLM or DMLS metal works.

How does metal 3D printing work? The basic manufacturing process for SLM and DMLS is very similar.

1. The printing chamber is first filled with an inert gas (such as argon) to minimize the oxidation of the metal powder. It then heats up to the optimum operating temperature.
2. A layer of powder is spread over the platform, a powerful laser makes passes along a predetermined path in the program, fusing the metal particles together and creating the next layer.
3. When the sintering process is completed, the platform moves down 1 layer. Next, another thin layer of metal powder is applied. The process is repeated until the entire model is printed.

When the printing process is completed, the metal powder already has strong bonds in the structure. Unlike the SLS process, parts are attached to the platform via support structures. The support in metal 3D printing is created from the same material as the base part. This condition is necessary to reduce deformations that may occur due to high processing temperatures.
When the 3D printer's chamber cools down to room temperature, excess powder is removed manually, such as with a brush. The parts are then typically heat treated while they are still attached to the platform. This is done to relieve any residual stresses. They can then be further processed. The removal of the part from the platform occurs by means of sawing.

Scheme of operation of a 3D printer for metal.

In SLM and DMLS, almost all process parameters are set by the manufacturer. The layer height used in metal 3D printing varies from 20 to 50 microns and depends on the properties of the metal powder (fluidity, particle size distribution, shape, etc.).
The basic size of the print area on metal 3D printers is 200 x 150 x 150 mm, but there are also larger sizes of the working area. Printing accuracy is from 50 - 100 microns. As of 2020, metal 3D printers start at $150,000. For example, our company offers 3D metal printers from BLT.
metal 3D printers can be used for small batch production, but the 3D printing capabilities of such systems are more like those of mass production on FDM or SLA machines.
The metal powder in SLM and DMLS is recyclable: typically less than 5% is consumed. After each impression, the unused powder is collected and sieved, and then topped up with fresh material to the level required for the next production.
Waste in metal printing, are supports (support structures, without which it will not be possible to achieve a successful result). With too much support on the manufactured parts, the cost of the entire production will increase accordingly.

Adhesion between coats.


3D metal printing on BLT 3D printers

SLM and DMLS metal parts have almost isotropic mechanical and thermal properties. They are hard and have very little internal porosity (less than 0.2% in 3D printed condition and virtually non-existent after processing).
Metal printed parts have higher strength and hardness and are often more flexible than traditionally made parts. However, such metal becomes “tired” faster.

3D model support structure and part orientation on the work platform.

Support structures are always required when printing with metal, due to the very high processing temperatures. They are usually built using a lattice pattern.

Supports in metal 3D printing perform 3 functions:

• They form the basis for creating the first layer of the part.
• They secure the part to the platform and prevent it from deforming.
• They act as a heat sink, removing heat from the model.

Parts are often oriented at an angle. However, this will increase the amount of support required, the printing time, and ultimately the overall cost.
Deformation can also be minimized with laser sintering templates. This strategy prevents the accumulation of residual stresses in any particular direction and adds a characteristic surface texture to the part.

Since the cost of metal printing is very high, software simulations are often used to predict how a part will behave during processing. These topology optimization algorithms are otherwise used not only to increase mechanical performance and create lightweight parts, but also to minimize the need for supports and the likelihood of part distortion.

Hollow sections and lightweight structures.


An example of printing on a BLT 3D printer

Unlike polymer powder melt processes such as SLS, large hollow sections are not typically used in metal printing as the support would be very difficult to remove, if at all possible.
For internal channels larger than Ø 8 mm, it is recommended to use diamond or teardrop cross-sections instead of round ones, as they do not require support. More detailed recommendations on the design of SLM and DMLS can be found in other articles on this topic.

As an alternative to hollow sections, parts can be made with sheath and cores, which in turn are machined using different laser power and pass speeds, resulting in different material properties. The use of sheath and cores is very useful when making parts with a large solid section, as it greatly reduces printing time and reduces the chance of warping.

The use of a lattice structure is a common strategy in metal 3D printing to reduce part weight. Topology optimization algorithms can also help design organic lightweight shapes.

Consumables for 3D metal printing.

SLM and DMLS technologies can produce parts from a wide range of metals and metal alloys, including aluminum, stainless steel, titanium, cobalt, chromium and inconel. These materials meet the needs of most industrial applications, from aerospace to medical applications. Precious metals such as gold, platinum, palladium and silver can also be processed, but their use is of a minor nature and is mainly limited to jewelry making.

The cost of metal powder is very high. For example, a kilogram of 316 stainless steel powder costs approximately $350-$450. For this reason, minimizing part volume and the need for supports is key to maintaining optimal manufacturing cost.
The main advantage of metal 3D printing is its compatibility with high-strength materials such as nickel or cobalt-chromium superalloys, which are very difficult to machine with traditional methods. Significant cost and time savings can be achieved by using metal 3D printing to create a near-clean shape part. Subsequently, such a part can be processed to a very high surface quality.

Metal post-processing.

Various post methods. treatments are used to improve the mechanical properties, accuracy and appearance of metal printed products.
Mandatory post-processing steps include the removal of loose powder and support structures, while heat treatment (heat annealing) is typically used to relieve residual stresses and improve the mechanical properties of the part.

CNC machining can be used for critical features (such as holes or threads). Sandblasting, plating, polishing, and micro-machining can improve the surface quality and fatigue strength of a metal printed part.

Advantages and disadvantages of metal 3D printing.

Pros:

1. Metal 3D printing can be used to make complex custom parts, with geometries that traditional manufacturing methods cannot provide.
2. Metal 3D printed parts can be optimized to increase their performance with minimal weight.
3. Metal 3D printed parts have excellent physical properties, metal 3D printers can print a wide range of metals and alloys. Includes difficult-to-machine materials and metal superalloys.

Cons:

1. Manufacturing costs associated with metal 3D printing are high. The cost of consumables is from $ 500 per 1 kg.
2. The size of the working area in metal 3D printers is limited.

Conclusions.

• Metal 3D printing is most suitable for complex, one-piece parts that are difficult or very expensive to manufacture using traditional methods, such as CNC.
• Reducing the need for building supports, will significantly reduce the cost of printing with metal.
• 3D printed metal parts have excellent mechanical properties and can be made from a wide range of engineering materials, including superalloys.

And that's all we have! We hope the article was useful to you.

Catalog of 3D printers for metal BLT

You can purchase metal 3d printers, as well as any other 3d printers and CNC machines, by contacting us:

• By email: [email protected]

• By phone: 8(800)775-86-69

• Or on our website: http://3dtool.ru

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Steel 3D Printing - Quick Guide

Any metal 3D printing technology can print with steel. This is the most popular material. But which steel grades and which technology is best for your application? Will printed steel parts really be as strong and durable as traditionally made parts?

Let's see how a 3D printed steel part revolutionizes manufacturing and opens the door to new applications in aerospace, medical equipment, automotive, tool making, heavy industry, architecture and more. In addition, more affordable desktop printers are expanding the scope and scope of real steel 3D printed parts.

Strength of steel printed parts.

Cast steel part (left), 3D printed version (center). On the right, a fully 3D printed hinge requires no assembly. (Source: Desktop Metal)

The most common question when it comes to a 3D printed metal model is "Will it be as strong as a forged or cast part?" ?". The short answer is yes... and no.

3D printed steel parts can be just as strong, and sometimes even stronger, than those made in the traditional way. It depends on many factors such as: end use, type of steel, choice of 3D printing method, post-processing and shape of the part. Also, the comparison depends on which of the strength characteristics you focus on: tensile strength, static load strength, fatigue strength, etc.

Parts printed from steel are used in the aerospace industry, for the military, as well as, for example, for the manufacture of a footbridge, shown below. Therefore, the strength of printed products is beyond doubt, but let's take a closer look.

Queen Maxima of the Netherlands officially opens a 3D printed metal bridge. Photo by Adriaande Groot (Source: MX3D)

A 3D printed or laser powder sintered (LPBF) steel part has a finer grain structure than cast metal products. This provides better tensile strength characteristics, but in other respects the cast parts are currently still stronger. Most often, LPBF 3D printing is used to replace cast components, but in some cases, 3D printed components can replace forged parts.

One study showed that, under certain conditions, stainless steel parts made using LPBF 3D printers were three times stronger than parts made from the same steel using the traditional method.

In experiments comparing 3D printed steel parts to traditionally made steel parts, researchers create identical parts using two methods and compare their performance. However, head-to-head comparison of details is only part of the big picture.

The main advantage of printing with steel is not only its strength, but also the unique ability to create internal channels and lattice fillings in parts, which is impossible with traditional manufacturing methods. Metal 3D printing makes it possible to produce parts faster than traditional production, since this method does not require the use of special equipment and tools, it allows you to create assemblies as a whole, eliminating the need for subsequent assembly and welding. Designing a printed part usually means that less metal is needed to make it, and therefore less weight, for the same strength.

MX3D Wire Arc Additive Manufacturing (WAAM) printed steel architectural support (Source: MX3D)

Steel 3D printing is also more stable and cost effective as it reduces waste. When using subtractive manufacturing methods, such as CNC machining, you make a part by cutting it out of a large one, with a lot of waste. With additive manufacturing, you only use the material you need to make the finished product.

Steel 3D printing is not intended to replace traditional methods in all areas, but it may be a better choice for a wide range of applications. Particularly when the required parts are unique and designed for specific applications, such as rocket engines, racing cars or the oil and gas industry. 3D printing is the fastest and most flexible technology for mass production and prototype production. For military and industrial applications, steel 3D printing is a faster and more efficient way to create individual parts for vehicles and machines. Stainless steel 3D printing is rapidly finding applications in medicine to create unique surgical instruments and implants.

If you know what characteristics your final product should have (tensile strength, compressive strength, hardness, density, etc.), then all these parameters can be incorporated into the product at the production stage.

Kinds of steel for 3D printing

Metal powder is the most used metal material for 3D printing (Source: GKN Additive)

There are thousands of kinds of different steel grades and alloys with different mechanical properties, used in traditional manufacturing but in 3D printing there are only a few dozen of them, and some of them are unique, created specifically for this technology. Among the steel options, the following can be distinguished:

  • Stainless steel (316L, 304L , 17-4PH, 15-5PH, 420, 254, Ph2, GP1, 630, 410).

  • Tool steel (D2, M2, h23, h21, MS1, 1.2709).

  • Low alloy steel (4140).

  • Structural alloyed (20MnCr5).

Recently, unique alloys have been developed specifically for 3D printing, designed to solve the problems that occur with classical production methods.

For example, 3D printer manufacturer Desktop Metal released a patented stainless steel in 2022 that the company says combines the tensile strength, ductility, and corrosion resistance of 13-8 PH stainless steel, combined with the hardness low alloy steel like 4140. The company says customers can go to market with this material and skip the galvanizing step to protect products from corrosion.

ExOne offers two special blends of steel and bronze that the company says allows 3D printed steel parts to have enhanced corrosion resistance while being easy to machine and polish.

While most of the metal powders used in 3D printing are similar to those used for other manufacturing methods, their numbers are on the rise as more companies adopt the technology. Some metal powder manufacturers, such as GKN, also make custom powders for specific 3D printing applications.

How to print with steel

The strength, properties, and applications of 3D printed steel products largely depend on which 3D printing technology you use. Some methods produce stronger parts, other methods provide better hardness or abrasion resistance, and some technologies are simply very fast.

Below are the main metal 3D printing methods, their properties and some of the most common application examples.

Fused Deposition Printing (FDM)

BCN3D's Epsilon printer extrudes metal filament from stainless steel (Source: BCN3D) as more printer manufacturers certify metallic filaments for use on their printers, such as Ultimaker, BCN3D, Makerbot, Raise3D. Raise3D has recently released a complete metal printing suite - Metalfuse (3D printer, debinding oven and sintering oven). This method is still much more popular for printing plastics, but with new plastic filaments filled with stainless steel powder, strong metal parts can be produced.

FDM media was once limited to thermoplastics. Companies like BASF Forward AM and The Virtual Foundry now offer metal filaments that can be used on almost any FDM printer as long as it has a hardened steel nozzle for abrasive media.

These materials are approximately 80% metal and 20% plastic. After printing, the post-processing process removes the plastic, resulting in 100% metal parts.

Due to the removal of the bonding plastic, FDM metal parts shrink during post-processing. The amount of shrinkage is constant and can be taken into account in CAD systems, which allows to obtain relatively accurate finished parts.

Forward AM's 316L Stainless Steel Ultrafuse filament produces finished parts with material properties that the company claims are comparable to injection molded metal parts.

(Source: BCN3D)

While 3D printing with metallic materials may not be suitable for high strength applications such as aerospace, the economics of producing simple metal components without critical loads on an affordable FDM printer can outweigh the impossibility of applying them in some areas.

Metal prototype parts and finished parts that will not be subjected to extreme stress are ideal uses for this technology.

Bound Metal Deposition (BMD)

Desktop Metal's Studio System 3D printer used bonded metal bars that were extruded layer by layer to form a metal part. Metal mesh deposition method (BMD) or bonded powder extrusion (BPE) is a 3D printing process based on extrusion. This method uses bonded metal rods or bonded powdered metal filaments, which consist of a much higher percentage of metal powder than the filaments used in FDM. As with FDM, post-treatment to remove the binder and heat treatment in a final sintering oven are required.

There are only a few 3D printers using this method such as Desktop Metal, Markforged and more recently 3DGence, but more companies are entering this market, so stay tuned. These printers are valued as a convenient solution for office 3D metal printing, they are more expensive than most FDM printers, but cheaper than the powder-based metal 3D printing technologies described below.

These printers use their own proprietary filament. Desktop Metal and Markforged offer four types of steel.

Ideal niches for this technology are metal prototype parts, where it is necessary to test the functionality of a part before mass production using traditional methods. Popular applications are molds, punching dies, nozzles, impellers, fasteners and heat exchangers.

For example, Shukla Medical uses Markforged's Metal X printer to print steel prototypes of its orthopedic implant removal instruments.

Laser powder sintering.

Laser powder sintering technology uses one or more lasers to melt powdered metal into a desired shape layer by layer (Source: GE Additive) metal printing. This technology is used by 80% of all metal 3D printers on the market.

This method uses powerful lasers to selectively sinter metal powder layer by layer.

LPBF 3D printers come in a wide range of sizes, prices and laser powers. These and other characteristics affect the properties of the finished part, print speed and other parameters of the finished products.

Steel and steel alloys are the most popular material for LPBF equipment and, unlike FDM and BMD, metal powders are commercially available as they are most commonly used in traditional production methods.

LPBF is a technology that maximizes the quality of a 3D printed part. Applications include aerospace components such as monolithic thrust chambers, rocket engine components and heat exchangers, molds, tools and other applications, as well as high wear parts and surgical instruments.

Binder Jetting

Binder 3D printing technology uses metal powder and a binder to form metal parts (Sorrce: ExOne) binder, and not with a laser. During post-processing, the binder is removed.

Binder application stands out for its high printing speed compared to other 3D printing methods or traditional manufacturing, and metal parts made with this technology have material properties equivalent to those made by metal injection molding.

The number of manufacturers producing metal-bonded inkjet 3D printers is much smaller than that of LPBF machines. Leading manufacturers include ExOne, Desktop Metal, Digital Metal, GE Additive and HP.

Binder blasting is ideal for medium to high volume production of metal tools and spare parts.

In fact, HP claims that its Metal Jet 3D printer was designed specifically for mass production of 316L stainless steel products. HP has partnered with Parmatech to produce metal parts for the medical industry. Pennsylvania-based ExOne uses this technology to manufacture hard metal cutting tools and tool steels.

Electron Beam Melting (EBM)

(Source: GE Additive)

Electron Beam Melting (EBM) is another powder cladding technology. It works in a similar way to selective laser melting (SLM), but instead of using a laser as the energy source, it uses a much more powerful beam of charged particles.

The recoater moves the powder onto the printing plate and an electron beam selectively melts each layer of powder. After each layer is printed, the plate is lowered and another one is applied on top of the previous layer.

EBM can be much faster than SLM, but SLM produces smoother and more accurate pieces. The electron beam is wider than the laser beam, so EBM cannot produce the same precise parts as SLM. Another difference is that the manufacturing process takes place in a vacuum chamber, which reduces the amount of impurities in the material that can lead to defects. That is why EBM is often chosen for printing components for the aerospace, automotive, defense, petrochemical and medical implant industries.

Titanium is the most popular metal for most EBM applications, however steel can be used.

Cold Spray

(Source: Impact Innovations)

Cold spray 3D printing is done by injecting metal powders through a jet nozzle into a supersonic stream of pressurized gases such as air, nitrogen, or helium. The process is called "cold" because the metal particles do not melt, but hit the metal substrate and adhere to its surface during the so-called plastic deformation.

Cold spray printed products are not prone to porosity, thermal cracking and other defects associated with melt-based technologies. This method has several advantages over other production methods. The technology is used in the military and aerospace industries around the world. For example, the US Army uses cold spray to repair the mounts of a worn Bradley 25mm steel turret gun.

In the automotive industry, cold spray steel is used for crash repairs because the high strength steel substrates in cars can be susceptible to thermal repair methods such as welding.

Direct Energy Deposition (DED) and Wire Arc Additive Manufacturing (WAAM)

WAAM Steel Parts from MX3D (Source: MX3D)

Direct Energy Deposition (DED) uses welding powder or wire that enters through a nozzle and is fed into the power source to melt the metal. A melt region is created and applied to the substrate. DED is a new process, reminiscent of an old building technology known as "cladding", in which a coating is applied to a substrate, often for thermal insulation or weather resistance. DED is useful for fabricating large objects as a whole, as well as complex geometries that require extensive machining. DED can get such parts much closer to finished than traditional CNC machining.

Because DED uses a coating process, it can be used to add complex geometries to existing steel parts, thus combining complexity with cost reduction. For example, the French company AddUp advertises a rocket nozzle that uses a preformed large 304 stainless steel hopper cone printed with an isogrid structure, usually made from a larger piece by traditional methods.

A technology related to DED is wire-arc additive manufacturing (WAAM). Instead of powder, WAAM uses a metal wire that is melted by an electric arc. The process is controlled by robotic arms. WAAM is also capable of producing large-sized metal parts, as demonstrated by the Dutch company MX3D and its nine thousand-pound 41-foot stainless steel bridge in Amsterdam, as well as an oil and gas equipment repair part, proving that parts can be made in the field.

Micro 3D printing

Micro parts printed from steel (Source: 3D MicroPrint)

Micro scale additive manufacturing, or micro 3D printing, can produce products with a resolution of a few microns (or less).

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