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High-quality Industrial Metal 3D Printing: DMLS and Binder Jetting Service |
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What is Metal 3D Printing?
Metal 3D printing, an additive manufacturing process, produces parts by fusing together metal particles layer by layer to form a metal part. It is often chosen as an alternative to CNC machining or metal casting because it can produce parts with the strength and durability of metal while also taking advantage of the design freedoms afforded by 3D printing. It can produce complex designs including lattices and topology-generated structures, both which are impossible to manufacture via traditional CNC machining.
Use the 3D viewer above to preview Xometry’s part rendering features.
Advantages of Metal 3D Printing
Metal 3D printing is advantageous because it can produce high-performance, complex metal parts that are suited for a range of end environments. Metal 3D printed parts are isotropic, meaning they have even, multi-directional strength, and have the superior mechanical properties of metals like aluminum, stainless steel, titanium, Inconel, tool steel, and stainless steel-bronze composites.
3D metal printing can also be used to combine multiple assembly components into one part. This typically results in a stronger structure by reducing the points of failure introduced by threads and inserts.
With metal 3D printing, CAD file information is sent directly to a printer meaning parts are typically cheaper and faster than producing machined metal parts. Machined metal parts have overhead costs like tooling set-up and longer machining time. Most 3D print metal parts can be turned around in less than a week.
Metal 3D Printing
Direct Metal Laser Sintering (DMLS) 3D Printing Service
Upload your CAD files to get an instant quote on metal prototypes and production parts. Free shipping on all US orders.
Direct Metal Laser Sintering (DMLS) 3D Printing Service
Metal Binder Jetting 3D Printing Service
Upload your CAD files to get an instant quote on parts.
Free shipping on all US orders.
Metal Binder Jetting 3D Printing Service
Choosing Between DMLS or Binder Jet Metal
Xometry's 3D metal printing services include direct metal laser sintering (DMLS) and metal binder jetting as options. These processes are suitable for creating metal prototypes, tooling, and production parts on demand. However, each metal 3D printing process uses different metals and fusing methods, resulting in parts with different mechanical properties, prices, and lead times.
Overview of Direct Metal Laser Sintering
DMLS, also known as selective laser melting (SLM), uses a laser to selectively fuse sections of fine metallic powder from the ground up. DMLS is advantageous because it can produce fully dense parts for fluid transfer applications. DMLS can use aluminum AlSi10Mg, stainless steel, maraging steel, tool steel, cobalt chrome, and Inconel. It is more expensive than binder jetting but has superior mechanical properties for high-precision applications.
Learn more about DMLS materials, post-processing, tolerances, and applications →
Overview of Binder Jet 3D Printing
Metal binder jet is a multi-step process that first selectively deposits a binding agent onto a metal powder bed, layer by layer, to hold the metal powder in a 3-dimensional shape. This resulting shape is left to cure, then put into a furnace to sinter or be infiltrated with bronze. Binder jet parts with overhanging features are supported by loose powder on all sides of the part, which usually eliminates the need for post-processing.
Binder jetting is a popular metal 3D printing choice because parts are cheap and fast, which allows for higher volume, cost-effective production. Binder jetting metal parts are excellent for functional prototypes or end-use parts with a density of ~95% or greater. Metal binder jetting is also frequently used by artists and hobbyists because of its ability to create complex features at a fraction of the cost of DMLS or machining.
Unlike DMLS, binder jet parts are prone to shrinkage so engineers should design parts with design-for-manufacturing principles in mind. This could include scaling their CAD model size by 1-2% and enlarging holes. Learn more about binder jetting materials, post-processing, tolerances, and applications →
Direct Metal Laser Sintering Material Properties
- Aluminum AlSi10Mg
- Stainless Steel 17-4
- Stainless Steel 316/L
New!
Metal Binder Jetting Material Properties
- X1 Metal 420i (420 stainless infiltrated with bronze)
- Six finishes available
Applications of Metal 3D Printing in Various Industries
Metal 3D printing can be used for rapid industrial tooling, where the metal 3D print can be used for parts with complex curvatures and small, thin-walled parts like conformal jigs and fixtures, stamps, dies, and cutting inserts.
For other industries like consumer products, robotics, aerospace, and defense, metal 3D printing can be used for integrated fastening features, end-effectors, and metal lattice structures.
Since metal 3D printed parts have excellent durability and strength, they can be used in fully functional late-stage prototypes or end-use parts for any of the above applications.
Read about how this global distributor uses DMLS for custom shading systems, including high-strength coupling brackets and zipper assemblies.
Ready to get started on your custom metal 3D printing quote?
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Why Choose Xometry for 3D Metal Printing Service?
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Choose from millions of possible combinations of materials, finishes, tolerances, markings, and certifications for your order.
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We are ISO 9001:2015, ISO 13485, and AS9100D certified. Only the top shops that apply to become Suppliers make it through our qualification process.
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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.
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
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 QuoteHigh-precision aluminum 3D printing at Sprint 3D!
aluminum 3D printing is a relatively new technology in the production of high strength metal products. Using aluminum alloys, you can create almost any product - from home decor and souvenirs to parts of industrial equipment or even aircraft.
SPRINT3D is already using 3D printing technology with aluminum for its customers. We use the latest equipment - Renishaw AM400 (SLM) aluminum 3D printer that allows you to grow products of almost any complexity based on metal powders.
We invite you to learn more about aluminum 3D printing, features and benefits.
Why 3D printing with aluminum is a new step in production
First and foremost are the materials used. Not just powdered aluminum is used. The material itself is quite malleable. But when nanoparticles are mixed with raw materials, crystallization occurs, which greatly increases the strength of finished products and prevents the formation of cracks during their hardening.
For the first time, the technology has been successfully applied in the aerospace industry. It was practically inaccessible to the general public. Commercial/Industrial
Aluminum 3D Printer is a new phenomenon. But even today it solves the most difficult tasks:
- Allows small-scale production of metal products. The main advantage is high geometric accuracy, which was previously unavailable.
- Suitable for low volume production and prototype printing. For example, to check the ergonomics of the product and carry out the necessary checks.
- This is the best choice for tool making. Complexity, dimensions, geometry - everything is individual.
We use the most suitable production material, aluminum alloy AlSi10Mg-0403. It contains aluminum alloyed with silicon (no more than 10%), magnesium, and other components in small quantities. Thanks to silicon, the alloy becomes much stronger than pure aluminum. In addition, an oxide layer is formed on the surface of the printed products, which has increased corrosion resistance. It can even be enhanced using chemical anodizing technology.
4 key benefits of
3D printing with aluminumThere are many more benefits, but we will focus on the main ones:
- Increased flexibility in design and production. For example, the technology allows the creation of complex internal channels, mesh structures and bionic elements.
Previously, this required the serious work of specialists and the introduction of expensive technologies into production. - Short design and production times. 3D printing with aluminum is much easier and faster than creating similar products using other methods. First of all, due to the maximum automation of the process.
- Reduced finished product weight. Similar blanks made using other technologies weigh more. This puts some restrictions in terms of operation and their implementation in various units, tools and mechanisms.
- Reduced financial costs in production. With the same budget and volume of material, it is possible to produce a numerically large batch of products and, in general, reduce costs by at least a few percent.
Existing mathematical models that have been used for 3D printing on other equipment can be quickly and inexpensively optimized for 3D printing with aluminum on new equipment. At all stages of production, product control is ensured.
For this we use computed tomography. This allows you to eliminate even the slightest defects.
Our
AM400AM400 aluminum 3D printer is a versatile printer that can work not only with the mentioned AlSi10Mg-0403, but also other metal powders. But we use it mainly in conjunction with aluminum powder materials. One of the key advantages of this printer is the ability to quickly change the printing system between different types of metal. This reduces production time and allows different materials to be processed on the same machine.
Main parameters of the model:
- Working area: 25 cm × 25 cm x 30 cm.
- The level of argon use is at least 60% lower than in analogues.
The printer is already widely used in the aerospace industry. The reason is the ability to reduce the weight of the product, while maintaining all its parameters and strength indicators. The AM400 allows you to create particularly complex parts.
For example, with complex internal cooling circuits. Previously, this was not possible due to the use of outdated metal casting methods. They did not allow creating models of high complexity.
The AM400 aluminum 3D printer is ideal for small batch production. But if necessary, it can also be used for mass production.
Selective Laser Melting Technology and Features
The AM400 supports the SLM laser melting technique. This is one of the newest destinations used in the most demanding segments:
- engineering sector;
- space/aerospace;
- production of spare parts and structural products.
3D printing with aluminum paired with SLM technology allows you to create functional metal products with increased construction accuracy. For example, you can implement complex systems of channels within the product for cooling.
Key features of the SLM:
- The vacuum technology used saves 60 to 80% argon.
- Preparation of equipment for production - no more than 15 minutes.
- Focal spot - 70 microns. This gives an improved quality of model building in this class.
- The powders used are practically not in contact with the atmosphere.
- For R&D powders, the built-in small chamber can be used.
- Renishaw branded encoders guarantee increased durability.
And this is only a small part of all the benefits.
Our offer
SPRINT3D prints metal parts, engine components, components of complex metal structures. We also carry out 3D printing with aluminum for the medical industry.
Contact our manager to discuss production possibilities, terms and main parameters of future products. We will provide convenient conditions, a comfortable price and standardized quality of 3D printing of all products. If necessary, we will offer alternative production options.
You can get advice, discuss the order and find out the price of production on the website through a special form or by phone number 8 (495) 740-51-70.
You may be interested in
Our company offers 3D aluminum printing using Selective Laser Melting technology. SLM technology allows you to create structural parts that are close in parameters to casting. Complex shapes are possible with internal structures that cannot be replicated by casting or milling.
We have a Concept Laser M2 Cusing machine for printing with AlSi10Mg powder alloy. This is a 3D printer for layer-by-layer printing with powder metals and alloys in a nitrogen or argon environment.
During the printing process, a thin layer of aluminum powder is applied to the platform, where it is fused by a laser along the outlines of the future part. The platform then lowers slightly and the process repeats. As a result, we get a strong anisotropic part, as close as possible in terms of characteristics to casting.
Aluminum printing examples
Aluminum 3D printing prices
| Technology | Equipment | Region | Layer, µm | Accuracy, mm | Materials | Price (r/cm3) |
|---|---|---|---|---|---|---|
| SLM | Concept Laser M2 | 250x250x280 | 20-80 | +-0. 05 | 12X18H10T (stainless steel) 03Х17Н12М2 AlSi10Mg (aluminum) | 500r/cm3 500r/cm3 400r/cm3 |
| Manual post-processing | Cleaning of support material, surface grinding and polishing, painting work | 1500 rub/man-hour | ||||
| 3D modeling | Create 3D models from drawings or templates | 2500 rub/man-hour | ||||
SLM and DMLS aluminum printing technologies are used in completely different areas: from the creation of new parts for the aerospace industry, to the printing of broken parts for cars and other equipment. Unlike traditional manufacturing methods such as milling and casting, the selective layer-by-layer fusion process has much fewer restrictions on shapes, negative angles, cavities, and so on.
Why is powder metal printing so good? First of all - small-scale.
For one medium or small part made of aluminum, casters and millers may simply not take it - the preparatory procedures are very expensive. Making molds for casting, as well as preparing and debugging a CNC program, require time and money. And one detail will be easily printed for you.
For 3D printing with aluminum, we use AlSi10Mg powder alloy - its composition is aluminum, about 10 percent silicon and magnesium. Lightweight and strong, this alloy is great for rapid prototyping and making new parts.
SLM printing with Al powder is widely used in the aerospace industry. Lightweight and durable parts with the ability to create internal cavities and cooling channels are indispensable for modern aircraft manufacturing. Also, this technology began to be used to create custom cooling radiators in electronics.
How is aluminum printed on a 3D printer? First, a thin first layer of powder is applied, with a thickness of 25-100 microns. Then the laser beam goes around the desired areas, fusing the powder to the metal.
Then a layer of powder is applied again and the process is repeated. Of course, a lot of experience of the staff is necessary, the specialist must correctly locate the part and support in the specialized software. 3D printing parameters may also differ for different alloys and different powders with different grain sizes. And finally, post-processing in the form of tumbling or grinding may be required.
Why order from us? Our company has its own production, with its own 3D printers, including those for metal. This allows us to quickly fulfill your orders and keep prices low. Our employees have extensive experience in the field of additive technologies, which allows us to perform prototyping work as efficiently as possible.
Advantages of 3D printing with aluminum
The main advantages of powder printing with aluminum alloys.
Speed
Printing an aluminum (silumin) part is much faster than making it with traditional metal casting and CNC milling.
