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Metal 3D Printing Service for Custom Parts
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Proto Labs, Inc.
5540 Pioneer Creek Dr.
Maple Plain, MN 55359
United StatesP: 877.479.3680
F: 763.479.2679
E: [email protected]Best-in-Class Online Quoting
After uploading your part design, you'll receive an online quote that includes manufacturing analysis to help improve part manufacturability. Within your quote, you can also adjust quantity and material and see price changes in real-time.
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Jump to Section→ 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.
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
Design Tip
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
White Paper
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
Blog
Inconel 718: A Workhorse Material for Additive Manufacturing
Inconel 718 is a go-to material for additive manufacturing of metal parts.
Read Blog
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
Instant quotes on 3D-printed parts
Get A QuoteDirect Metal Laser Sintering [DMLS] Parts On Demand
Direct Metal Laser Sintering [DMLS] Parts On Demand - StratasysUSA & Canada
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What Is Direct Metal Laser Sintering?
Direct Metal Laser Sintering (DMLS) is a direct metal laser melting (DMLM) or laser powder bed fusion (LPBF) technology that accurately forms complex geometries not possible with other metal manufacturing methods.
DMLS Part Strength
DMLS parts are stronger and denser than investment casted metal parts, and they can help you get to market first with faster turnaround times.
Metal 3D printing is an ideal process for complex oil and gas components, custom medical guides, part-consolidated aerospace parts and tough functional prototypes.
Streamlined Metal Parts with DMLS
Utilize the design freedom of DMLS and produce accurate metal components in less time than other manufacturing methods.
How Does Direct Metal Laser Sintering Work?
DMLS uses a precise, high-wattage laser to micro-weld powdered metals and alloys to form fully functional metal components from your CAD model.
DMLS parts are made with powdered materials like aluminum, stainless steel and titanium, as well as niche alloys like MONEL® K500 and Nickel Alloy 718.
Finishing DMLS Parts
Raw DMLS parts have a surface finish comparable to a fine investment casting part, and expert finishing services are sometimes needed.
Stratasys Direct offers a full suite of professional finishing operations, including precision machining, media blasting, surface grinders and milling.
Direct Metal Laser Sintering Quality Controls
To maintain critical quality control standards, we use a range of tools to inspect and ensure customer specifications. With international certification standards ISO 9001 and AS9100, we have stringent systems in place to guarantee quality and consistently are met.
We utilize tools like coordinate measuring machines, probes, cutup metallography processes and flow benches, hydrostatic pressure testing machines to guarantee quality is consistently met. DMLS materials build fully dense, corrosive resistant and highly robust metal parts that can be further treated through heat, coating and sterilization.
DMLM Products
Essentials
- The fastest way to manufacture with DMLM technology
- Produce geometries with high-strength metal alloys in one fluid build
- Hand-finishing with media blast
- Manufacture in Stainless Steel 316L or 17-4, Aluminum (AlSi10Mg), Cobalt Chrome, Nickel Alloy 625, and Titanium (Ti64)
A.
M.P. Specification- No spec? No problem! Our Additive Metal Process Spec provides production metal parts with DMLM technology
Customer Specification
- Adhering to customer-provided statement of work and process, material, and/or machine specifications. The ultimate level of control for your project and product
DMLM Discover
We’re ready to take on any challenge and push the boundaries of what’s possible with DMLM Discover – our custom solution for new and novel additive alloys and designs.
- Access materials in the early stages of development for DMLM
- Test custom manufacturing parameters for your project
Materials for 3D Printing Parts with DMLS
Stainless Steel 17-4 PH (As Built)
SS17-4PH is characterized by excellent weld-ability, good corrosion resistance, and mechanical properties
Learn more
Stainless Steel 316L (As Built)
SS316L is characterized by very good weld-ability, corrosion resistance, and mechanical properties including excellent ductility.
Learn more
Aluminum AlSi10Mg (As Built)
Casting grade alloy
Learn more
Nickel Alloy 625 (As Built)
Nickel based superalloy
Learn more
Nickel Alloy 718 (As Built)
High strength nickel base superalloy
Learn more
Nickel Alloy K500 (As Built)
Age-hardenable Nickel-Copper alloy
Learn more
Titanium Ti64 (As Built)
Titanium alloy
Learn more
Cobalt Chrome CoCrMo (As Built)
Metal alloy of cobalt and chromium
Learn more
Metal 3D Printing Applications of DMLS
PRODUCTION PARTS
Produce low-volume production metals parts with DMLS.
Read More
Functional Prototyping
Build tough and hardworking metal prototypes to test components in real-world applications.
Read More
Thermal Control Systems
Advance your thermal management capabilities with complex heat exchangers and heat pipes manufactured with DMLS.
DMLS Parts from 3D Printing Pioneers
Making a quality 3D printed part takes more than just a machine. It takes a responsive team behind the technology, running tests and working tirelessly to validate materials and processes.
At Stratasys Direct, our services are backed by more than the largest fleet of machines in North America; we have nearly thirty years in the industry and a team of engineers ready to assist with every step of your project.
DMLS Expertise You Can Trust
Years of experience with DMLS has led us to develop proprietary build styles, post-processing methods, and even led us into material development exploration.
Whatever your project need, we won’t rest until your requirements are met.
Frequently Asked Questions About DMLS
Are DMLS parts as strong as traditionally manufactured metal components?
Yes. The parts created with DMLS have mechanical properties equivalent to a cast metal part. Detailed information can be found on the DMLS materials page.
What is the porosity of DMLS parts?
DMLS parts can reach a 99.5% density. In fact, 3D printed metals are above industry standards for density testing.
What level of detail can be obtained with DMLS?
DMLS is available in several resolutions. At its highest resolution, the layer thickness is 0.0008” – 0.0015” Z and the X/Y resolution is 0.012” – 0.016”.
The minimum hole diameter is 0.035” – 0.045”. Read the DMLS design guidelines to learn more.
3D printing in metal - 3D printers
metal-printing
I was wondering about metal 3D printing (steel, aluminium), but after a short search on Google, I found only too expensive printers (markforged, desktop metal and a few other industrial ). Is there any less expensive printer on the market that can print metal parts?
@Martin Bariak, 👍11
Talk
4 answers
▲ 7
Ansalone and friends published Open Source Inexpensive Metal 3D Printer in IEEE Access :
This article reports on the development of an open source metal 3D printer. The metal 3D printer is controlled by an open source microcontroller and is a combination of a low cost commercial gas metal arc welder and a Rostock derivative, the deltabot RepRap. Bill of materials, electrical and mechanical design diagrams, and basic construction and operating procedures are provided.
, @ typo
▲ 2
You can do Lost Wax Casting, the actual equipment to do this is quite expensive unless you want to set up your own aluminum smelting forge.
Check it out, although you don't need a special printer for this.
There is also a way to metal your prints, this would require electricity and some nasty chemicals, but this is an alternative.
, @ Chris Diel
▲ 8
Printing on metal (direct) is done mainly in two types:
- Laser sintering (LS), in which a metal compound or alloy is sintered into a mold. For example, tungsten carbide is laser sintered. Common abbreviations are SLS, DML, and SML, but there are others.
- Laser melting, where the laser actually melts the metal into a spot. DMLS/DMLM (Direct Laser Metal Melting) and SLM (Selective Laser Melting) are currently at the forefront of development.
There is a side market for a custom machine that welds objects together, turning the whole thing into a single weld, but that's (strictly speaking) not printing, but welding.
What prevents open source machines from being available: Patents, more and more patents and more patents are still pending, and some of these patents contain the parts needed to print on metal, so they are banned. Only a few key laser melting/Laser sintering/Laser melting patents like this have lapsed at all so far. Some of the current patents for METAL printing, such as this (example: ~2019-2024), this one (example: ~2037) or this new one (example: ~2035), there are still years to go, so it will take some time.
Another factor is the market: there is only a small market for hobbyists who require metal printers, while the industrial demand is strong and the industry is willing to pay big money. Thus, there is little pressure on large manufacturers to produce small machines, while open source groups need to develop ways to get the right results without infringing on patents.
A more complete history of metal laser printing (and a little more information about what patents are actually relevant to the industry) can be found here.
, @ Trish
▲ 5
You can create a metal object using metal casting or using a special thread containing metal parts.
Metallic filament
You print with a special filament that is a mixture of metal and plastic. After printing, you heat the object to about 450°C to burn off the plastic and melt the metal grains together. You need a kiln. A DIY kiln costs about $150.
Before the firing process
After the firing process
The only thread I know of is Filamet from the Virtual Foundry. ColorFabb's copper filler contains just 30% metal combined with filament containing 80%.
- virtual foundry YouTube channel
- review: https://www.youtube.com/watch?v=hDIUCzV1vMg
-
3. Article
-
Price
- Copper Filament™: $110.00 / 1kg
- Bronze Filamet™: $165.00 / 1kg
- 316L Filamet™ Stainless Steel: $248. 00 / 1kg
Just remember that these threads are quite dense, which makes 1kg spools quite "short" and therefore even more expensive!
Casting
This method is very closed to investment casting. In short, you print an object, surround it with clay/green sand, heat it up to burn out the plastic, and pour liquid metal into it.
You can find an example of this technique on YouTube, but the method is pretty much the same as casting lost wax.
I found some metal printing experiments in the RepRap project, but didn't study them in detail.
- http://www.appropedia.org/Open-source_metal_3-D_printer
- https://reprap.org/wiki/MetalicaRap
- https://reprap.org/wiki/Metal_Delta_RepRap_v1
- https://reprap.org/wiki/The_most_Affordable_Desktop_metal_3D_printing
Bronze Paste and Paste Extruder
This is just an idea: perhaps you could take an FFF printer with a paste extruder and print with a paste containing a lot of metal in the paste. The print is then processed in an oven.
Here is a list of metal printing technologies from all3p.com List example:
- Desktop metal
- Stamped Metal X
- Digital Alloys
, @ amra
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 metal 3D printing SLM or DMLS 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 trajectory 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 produce 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.