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Desktop Metal Studio 3D Printer
DESKTOP METAL
STUDIO SYSTEM 2™An End-to-End Solution to 3D Print Complex Metal Parts In-HouseIntroducing the new Desktop Metal Studio 2 for metal 3D printing. The first end-to-end affordable solution for 3D printing complex metal parts in-house in a variety of metal alloys including stainless steel, copper and tool steels.
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- Overview
- Key Features
- Advantages
- How it Works
- Materials
- Applications
- Request a Quote
Accessible Metal 3D Printing
The Studio System 2 from Desktop Metal was created to enable engineers and design teams to produce complex metal parts faster, more accurately, and in a safe operating environment without the need for special facilities or dedicated operators. Just print and sinter; A two-step process that doesn’t require solvent debinder or tooling as in the case of MIM (metal injection molding).
Explore the Desktop Metal Studio by watching the video
Sophisticated Software
Powerful software creates build and sinter plans for every project and material. Automative supports and control parameters ensure a seamless 3D printing experience.
Maximize Productivity
3D print up to 24 cubic inches per day in a wide variety of metal materials. Maximum resolution for the printer is 50 μm
Built to Perform
The motion control system was built with encoded balls screws instead of belts, and combined with auto leveling and a heated build area you get excellent geometric fidelity and build success rates.
Affordable
Safe & Simple
Separable Supports
Precise, High-Quality Parts
Make Metal Work Faster
No more waiting for machined or cast parts.
Iterate faster by printing highly complex metal parts–without leaving the office.
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How It WorksA metal 3D printing process in 3 easy-to-manage steps
Step 1 – Prepare your files
Secure, web-based software fabricates from STL or CAD files, automatically generating supports and control parameters based on part geometry and material.
Step 2 – 3D Print
Layer by layer, a green part is shaped by extruding bound metal rods—metal powder held together by polymer binders—in a process called Bound Metal Deposition™.
Step 3 – Sinter
Once printed, parts are placed in the furnace. As the part is heated to temperatures near melting, the binder is removed and metal particles fuse together causing the part to densify up to 98%.
Introducing the new, swappable 250μm printhead that includes supporting software profiles. This enables new geometries and applications, resulting in achieving smaller parts and fine features with an improved surface.
There are camera’s everywhere, so why not put one in the in-chamber build plate? This camera captures live footage of the part as it prints, and is accessible in your web browser. Users now have complete insight of their part, and have the ability to monitor print success.
Stackable shelving is a new feature that increases part capacity of the debinder and furnace, giving greater throughput. Increased workload volume addresses bottlenecks typical at the debind sinter stages.
To achieve high quality parts, a new retort box design has been added to support thermal uniformity.
Eliminate some cost of consumables and achieve lower cost-per-part with external gas connections.
Studio Fleet is a custom and configurable metal 3D printing hardware solution for producing complex metal parts in low-mid volume.
MaterialsThe metallurgy behind the Studio System™ is built upon the material science and established powder supply chain of the metal injection molding (MIM) industry.
When combined with Desktop Metal’s expansive in-house expertise in material processing, binder compounds, and metal 3D printing, the result is high-quality metal parts with affordable material costs.
17-4 PH Stainless Steel
| Studio System 2
Material: 17-4 PH Stainless Steel
17-4 Stainless Steel is a precipitation hardening steel used in a wide range of industrial applications including those with mildly corrosive environments and high-strength requirements.
Specs- XY axis
- As sintered:
- Yield Strength: 695 MPa
- Ultimate Tensile Strength: 925 MPa
- Elongation at Break: 5.3%
- Hardness (HRC): 26
- Density (g/cc): 7.56
- As sintered:
- Manufacturing machinery
- Chemical processing
- Food processing
- Pump components
- Valving
- Fasteners
- Jigs and fixtures
- Bound Metal Deposition™
Learn More
316L Stainless Steel
| Studio System 2
Material: 316L Stainless Steel
Characterized by its corrosion resistance and performance at both high and low temperatures, 316L stainless steel is a fully austenitic steel ideal for harsh environments.
- Sintered:
- Ultimate Tensile Strength: 533 MPa
- Yield Strength: 169 MPa
- Elongation: 66%
- Hardness (HRB): 66
- Density (relative): 97%
- Chemical and petrochemical processing
- Food processing
- Laboratory equipment
- Medical devices
- Marine
- Jewelry
- Power generation
- Petroleum refining
- Water treatment
- Pulp and paper manufacturing
- Bound Metal Deposition™
Learn More
h23 | Studio System 2
Material: h23 Tool Steel
h23 tool steel is hot work steel with great hot hardness, resistance to thermal fatigue cracking, and stability in heat treatment.
This makes it an ideal metal for both hot and cold work tooling applications.
- Yield Strength:
- Sintered: 650 MPa
- Heat-treated: 1250 MPa
- Wrought, heat-treated: 1525
- Ultimate Tensile Strength:
- Sintered: 1325 MPa
- Heat-treated: 1720 MPa
- Wrought, heat-treated: 1950 MPa
- Elongation at Break:
- Sintered: 2.3%
- Heat-treated: 5.8%
- Wrought, heat-treated: 9%
- Hardness:
- Sintered: 35
- Heat-treated: 45
- Wrought, heat-treated: 54
- Density:
- Sintered: ≥93.5%
- Wrought, heat-treated: 100%
- Extrusion dies
- Injection molds
- Hot forging dies
- Die casting cores, inserts and cavities
- Bound Metal Deposition™
Learn More
4140 Chromoly Steel
| Studio System 2
Material: 4140 Chromoly Steel
One of the most versatile steels, 4140 steel is characterized by its toughness, high fatigue strength, and abrasion and impact resistance.
- Yield Strength:
- Heat Treated: 1060 MPa
- Wrought (heat-treated): 1500 MPa
- Ultimate Tensile Strength:
- Heat Treated: 1450 MPa
- Wrought (heat-treated): 1990 MPa
- Elongation at Break:
- HeatTreated: 5.5%
- Wrought (heat-treated): 10%
- Hardness (HRC):
- Heat Treated: 40
- Wrought (heat-treated): 52
- Density:
- Heat Treated: 95%
- Wrought (heat-treated): 100%
All-purpose steel industrial applications such as:
- Jigs and fixtures
- Automotive
- Bolts/Nuts
- Gears
- Steel couplings
- Bound Metal Deposition™
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Copper | Studio System 2
Material: Copper
Copper is characterized by its electrical and thermal conductivity and ductility, and it is ideal for electrical equipment, plumbing, and heat transfer applications.-kupit-v-soin-store.ru-4.png)
- Sintered:
- Ultimate Tensile Strength: 195 MPa
- Yield Strength: 45 MPa
- Elongation: 37%
- Density (g/cc): 8.75
- Consumer and industrial electronics
- Heat exchangers
- Antennas
- Inductors
- Bound Metal Deposition™
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Ti64 | Studio System 2
Material: Titanium Alloy
Ti64 is an alloy of titanium, aluminum, and vanadium with a high strength-to-weight ratio and corrosion resistance.
Specs- Ultimate Tensile Strength:
- Sintered: 845 MPa
- Yield Strength:
- Sintered: 730 MPa
- Elongation:
- Sintered: 17%
- Density (Relative): 97.
5%
A wide variety of high-performance applications such as:
- Specialty automotive components, including connecting rods and gearboxes for racing
- Prototyping of medical devices, including tweezers, forceps, clamps, suture instruments and more
- Consumer goods, including sporting goods and jewelry
- Bound Metal Deposition™
Learn More
Inconel 625 | Studio System 2
Material: Nickel Alloy IN 625
Inconel 625 (IN625) is a high nickel super alloy ideal for harsh environments in or out of water, characterized by its excellent strength, heat & corrosion resistance.
SpecsMechanical Properties [as sintered]:
- Ultimate tensile strength (Xy): 725 MPa
- Yield strength (Xy): 303 MPa
- Elongation at Break: 34%
- Hardness (HRB): 83.
5 - Young’s Modulus: 199 GPa
- Density: 8.2 g/cc
- Defense
- Aerospace
- Chemical
- Nuclear
- Bound Metal Deposition
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D2 Tool Steel | Studio System
Material: Corrosion Resistance Tool Steel
D2 tool steel is a versatile material that provides tooling grade strength while also offering corrosion resistance, a key benefit for conformally cooled applications.
SpecsMechanical Properties (After Quench & Temper):
- Transverse Rupture Strength (GPa): 3.1, ASTM B528
- Hardness (HRC): 56.5, ASTM E18
- Density: 7.5 g/cm³
Application
- Cutting components
- Conformally cooled injection molding inserts and cavities
- Cold forming tooling components
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Superior Properties
Similar to metal injection molding (MIM), the Desktop Metal Studio System leverages bulk sintering to achieve densities greater than 98%.
Part performance is similar to wrought alloys and it is possible to tune part density with closed-cell infill.
Materials Available
17-4 PH Stainless
316L Stainless
h23 Tool Steel
4140 Chrome Moly
Copper
Inconel 625 Superalloy
Kovar F-15
Additional Materials: By enabling the use of metal powders from the MIM industry, our systems have access to a wide range of existing materials—from steels and aluminum to superalloys and titanium.
Near-Net-Shape Parts
The Desktop Metal Studio system produces near-net-shape metal parts with the accuracy and layer resolution needed for functional prototyping and a variety of other applications. A seamless 3D printing experience, from printing through to sintering, is created with powerful software and automatic support generation.
Tight Tolerances
± .002 in/in (geometry dependent)
Remove Supports by Hand
The Desktop Metal Studio system does not require any wire EDM or machining to remove support structures.
Proprietary separable supports make it possible to remove support by hand because it is no bonded to the part. As a result, highly complex parts and print-in-place assemblies can be easily printed and put to use.
Bring Affordable Metal 3D Printing In-House
SEE COMPATIBLE ALLOYS
The HardwareThe Desktop Metal team designed the Studio 3D Printer to be the most accessible metal 3D printing solution to date.
With powerful web-based software, hand-removable support material, and fast material changes the
Studio System was designed from the ground up for seamless integration into your product development workflow.
The Studio Desktop Metal 3D printer extrudes bound metal rods similar to a plastic FDM system. Unlike laser-based DMLS 3D printers that selectively bond metal powders the Studio system does not require any special safety or facility requirements and creates the opportunity to produce closed-cell infill for lightweight structures as well as work with a wider range of metal alloys.
| Build Volume | 300 x 200 x 200 mm (12 x 8 x 8 in) |
| Build Chamber | Heated |
| Extruder Assembly | Dual quick-release print heads |
| Layer height (in green state) |
|
| Nozzle diameter (Build media) |
|
Download Spec Sheet
The Furnace
The Studio System 2 furnace is designed to be the easiest to use furnace ever made. It first heats parts to remove all binders, then increases the temperature to near-melting point to deliver industrial-strength sintering in an office-friendly package. Built-in temperature profiles tuned to every build and material ensure uniform heating and cooling without the residual stresses introduced in laser-based systems.
| Atmosphere | Partial-pressure sintering (vacuum-enabled) |
| Heating | SiC heating elements (4 sides) |
| Max Temperature | 1400 °C (2552 °F) |
| Workload surface area | 3,000 cm2 (465 in |
| Workload envelope | 300 x 200 x 170 mm (11.8 x 7.9 x 6.9 in) |
Download Spec Sheet
Software-Controlled Workflow
The Desktop Metal Studio system was designed as a complete workflow, with no third party equipment required. Every stage of the 3D printing process is fully automated and managed by software, making it simple to go from CAD to metal part.
Quick Material Changes
Compared to laser based systems, where material changes can pose safety risks and can take a week or more, the Studio 3D printer was designed to have swappable, safe-to-handle material catridges and quick release print heads.
Office-Friendly Sintering
A first of its kind, the sintering furnace has swappable aluminum gas canisters and optional hook ups for simple to manage gas. Built-in effluent filters, binder cold traps, safety fail safes, and detection systems make this system safe to use on the shop floor.
Expert Metallurgy Built-In
The Desktop Metal sintering oven combines unique materials profiles with part data to construct sintering plans for every part. With closed loop thermal control, real-time heating regulation throughout the sintering cycle is enabled ensuring every part is uniformly heated and cooled.
Low Volume Production with
Studio Fleet
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Stainless steel, copper, and tool steels are some of the many critical allows the Studio System brings to 3D printing. Every alloy goes through meticulous qualification by world-leading materials scientists, and our core materials consistently meet or exceed industry standards.
17-4 PH Material datasheet
| 17-4 PH Stainless steel for strength and corrosion resistance | AISI 4140 low alloy, mid-carbon steel for high strength and toughness | h23 tool steel for hardness and abrasion resistance at elevated temperatures |
| 316L Stainless steel for corrosion resistance at high temps | Copper for thermal and electrical conductivity | Inconel 625 superalloy for strength and corrosion resistance at high temperatures |
Easy two-step process
Printed parts are placed directly in the furnace. No need for a solvent debind, just print and sinter.
Safety First
Odor-free and environmentally safe due to no solvent debind phase. No need for additional ventilators or respirators. Studio System 2 allows users to get the system up and running in no time.
High Quality Parts
Difficult geometry (which requires tall, thin, complex supports) is now possible thanks to new material formulations and print/sinter profiles.
Software Controlled Workflow
No metallurgist or machinist experience is required with an automated print to sinter workflow powered by Fabricate software
ApplicationsMachine Bracket
Jigs & Fixtures Titanium 64 (Ti64) Alloy
This machine bracket has been designed by using a gyroid lattice infill and titanium in place of 17-4PH stainless steel in order to reduce weight and material while maintaining the required functional strength and stiffness.
Full DescriptionIt would be impossible to produce this part’s geometry using conventional manufacturing processes due to its complexity. Moreover, 3D printing this new design on the Studio System 2 in Ti64 leads to reducing the part’s weight by 59 percent.
Ti64 for Studio System 2 produces lightweight 3D printed parts due to its high strength-to-weight ratio, thus becoming ideal for countless applications from key industries such as aerospace and defence, automotive, oil and gas, and medical.
- Estimated saving in part weight: 55-60%
- Bound Metal Deposition (BMD)™
Flower Nozzle
Industrial Equipment 316L Stainless Steel
This flower nozzle was 3D printed with Desktop Metal Studio System 2™ and it is used to atomize fluid in industrial equipment.
Full DescriptionDue to the complex geometry, this type of part would typically be cast followed by extensive secondary machining. With the Studio System 2™, the nozzle can be 3D printed without the lead times and setup costs of casting, enabling one-off and small-batch orders.
Specs- Size (mm): 123 x 123 x 45
- Cost to print ($): 184.00
Bound Metal Deposition™
Lathe Gear
Industrial Equipment 17-4 PH Stainless Steel
This part is a replacement gear for a vintage lathe.
Metal 3D printing allows for the fabrication of legacy parts at a much lower cost.
In some cases, replacement parts are no longer available, either off the shelf or from the OEM (Original Equipment Manufacturer). Fabricating custom gears via hobbing and broaching is often expensive. With metal 3D printing, the manufacturing of such parts is possible at lower costs and reduced lead times.
Specs- Size (mm): 82 x 82 x 27
- Cost to print ($): 58.00
- Cost to machine ($): 260.67
- Savings vs. machining: 77.70%
Bound Metal Deposition™
APG Thread Checker Fixture
17-4 PH Stainless Steel (Studio System)
This fixture pushes a thread checker into a part on a manufacturing line. It stands for repeated use and must be easily produced to keep the manufacturing line up.
The fixture must be regularly replaced as it wears out. Printing the part with the Studio System eliminates CNC lead time and frees up the machine shop for more critical work.
Specs- Size (mm): 47 x 28 x 15
- Cost to print: $14.00
- Bound Metal Deposition™
Tri Manifold
Manufacturing Alloy 625
This part converges three flow paths into one via internal channels. These channels would be impossible to machine and instead would need to be drilled as straight holes and plugged.
Full DescriptionPrinting on the Studio System allows these channels to be designed for their function rather than their manufacturing method. This part can be produced in just a few days with very little hands-on work.
Specs- Size (mm): 108 x 101 x 98
- Cost to print: ($) 906.
00 - Cost to DMLS ($): 4069.28
- Savings vs. machining: 77.74%
Bound Metal Deposition™
Generative Piston Head
Generative Design, Prototyping 4140
Prototype piston head for a reciprocating engine, optimized with generative design. Typically CNC machined from aluminum alloy, pistons can be time-consuming and difficult to rapidly prototype and test.
Full DescriptionIt often takes months or even years to move from design to production. With the Studio System, various piston designs can be easily prototyped and tested—speeding up product development timelines, reducing time to market, and introducing new opportunities for optimization, including generative design—all while avoiding CNC backlog and lead times.
Specs- Size (mm): 105 x 105 x 54
- Cost to print ($): 271.
00 - Cost to machine ($): 568.13
- Savings vs. machining: 52.30%
Bound Metal Deposition™
YE6 Burner Tip
Tooling and Machinery 316L Stainless Steel
This burner tip was originally cast in the 1950s. With the Studio System, the company was able to recreate the part with properties similar to the original cast part, with no tooling cost or long lead times.
Full DescriptionThe quote for new tooling is usually in the tens of thousands of dollars. Thus, Studio System 2, a printer that was designed from the ground up for simple installation and use, allows for significant cost savings, especially when it comes to manufacturing obsolete parts at low costs and without compromising part quality.
Specs- Size (mm): 139 x 139 x 86
- Cost to print ($): 193.46
- Cost to machine: ($) 694.
00 - Cost reduction: 72.00%
Bound Metal Deposition™
Helical Heat Exchanger
Manufacturing Copper
This heat exchanger enables a much higher heat transfer rate than a traditionally manufactured part. Used in chemical processing to cool a hot gas as it flows through a pipe.
Full DescriptionThe Studio System allows for the complex geometry of the heat exchanger to easily be printed as a single component. It would not be manufacturable as one component via CNC machining due to its thin external fins and a complex, internal helical cooling channel.
Specs- Size (mm): 78 x 64 x 58
- Cost to print ($): 443.00
- Cost to machine ($): 2138.00
- Cost reduction: 79.28%
Bound Metal Deposition™
Zipper Mold
Material: h23 Tool Steel
This part is an injection mold insert for manufacturing zinc zippers.
The 3D printing of the mold inserts shortens production run lead time and allows rapid iteration and refinement of zipper designs. Using a high-resolution printhead allows for smaller parts with finer features, requiring less post-processing.
SpecsSize (mm): 46 x 27 x 18
Cost to print ($): 16.00
Bound Metal Deposition (BMD)™
Best metal 3D printers in 2022: comprehensive overview
What is the best metal 3D printer in 2022?
Over the past few years, there has been a surge in both supply and demand for metal 3D printers.
Manufacturers are launching metal additive manufacturing machines that are faster, easier to use, and more powerful with an increasing number of compatible metals.
Many businesses are adopting these 3D metal printing technologies to produce cost-effective metal parts and prototypes, benefiting as well from increased freedom of design linked to additive manufacturing.
They are suitable for a variety of industries such as aerospace, automotive, health, engineering, and more.
Although metal 3D printer prices have been slowly and slightly decreasing, these machines are still relatively expensive acquisitions, mostly ranging from $80K to almost $1M.
With our metal 3D printer selection, we aim to provide a comprehensive overview of what’s available from well-established and distributed brands, at various price points, and with different metal 3D printing technologies.
The best metal 3D printers in 2022
| Brand | Product | Build size | Country | Price Approximate starting prices based on supplier-provided information and public data. Prices may vary by region, over time and do not include additional products or services (taxes, shipping, accessories, training, installation, …). | |
|---|---|---|---|---|---|
| Markforged | Metal X (Gen 2) | 300 × 220 × 180 mm11. 81 × 8.66 × 7.09 in | United States | $ 99,500125 000 €88,260 £14,831,072 ¥ | Quote |
| Xact Metal | XM200C | 127 × 127 × 127 mm5 × 5 × 5 in | United States | $ 110,000100 000 €97,574 £16,396,160 ¥ | Quote |
| Pollen AM | Pam Series MC | ⌀ 300 x 300 mm | – | $ 140,000135 000 €124,186 £20,867,840 ¥ | Quote |
| TRUMPF | TruPrint 1000 | 100 × 100 × 100 mm3.94 × 3.94 × 3.94 in | – | $ 170,000170 000 €150,797 £25,339,520 ¥ | Quote |
| 3D Systems This brand is a certified partner from our network. | DMP Flex 100 | 100 × 100 × 80 mm3.94 × 3.94 × 3.15 in | – | $ 245,000245 000 €217,325 £36,518,720 ¥ | Quote |
| EOS | EOS M 100 | 100 × 100 × 95 mm3.94 × 3.94 × 3.74 in | Germany | $ 350,000350 000 €310,464 £52,169,600 ¥ | Quote |
| XJet | Carmel 700M | 501 × 140 × 200 mm19. 72 × 5.51 × 7.87 in | – | $ 599,000599 000 €531,337 £89,284,544 ¥ | Quote |
| Desktop Metal | Production System P-1 | 200 × 100 × 40 mm7.87 × 3.94 × 1.57 in | United States | upon request | Quote |
| Desktop Metal | Studio 2 | 300 × 200 × 200 mm11.81 × 7.87 × 7.87 in | United States | upon request | Quote |
| Digital Metal | DM P2500 | 203 × 180 × 69 mm7.99 × 7.09 × 2.72 in | – | upon request | Quote |
| Formalloy | L-Series | 1000 × 1000 × 1000 mm39.37 × 39.37 × 39.37 in | United States | upon request | Quote |
| GE Additive | Arcam EBM Spectra L | ⌀ 350 x 430 mm | United States | upon request | Quote |
| GE Additive | M2 Series 5 | 250 × 250 × 350 mm9.84 × 9.84 × 13.78 in | – | upon request | Quote |
| Renishaw | RenAM 500E | 245 × 245 × 335 mm9. 65 × 9.65 × 13.19 in | – | upon request | Quote |
| SLM Solutions | SLM 125 | 125 × 125 × 75 mm4.92 × 4.92 × 2.95 in | Germany | upon request | Quote |
| SPEE3D | LIGHTSPEE3D | 300 × 300 × 300 mm11.81 × 11.81 × 11.81 in | – | upon request | Quote |
| TRIDITIVE | AMCELL | ⌀ 300 x 350 mm | Spain | upon request | Quote |
| Velo3D | Sapphire | ⌀ 315 x 1000 mm | – | upon request | Quote |
Expand to see more specs
Technology: The technologies listed above are main categories of metal 3D printing technologies. Most manufacturers have their own branded technologies, which fall into the main categories that are listed in the table.
The products in the table are ranked by price (low to high).
| Brand | Product | Technology | Build size | Country | Price Approximate starting prices based on supplier-provided information and public data. | |
|---|---|---|---|---|---|---|
| Markforged | Metal X (Gen 2) | Extrusion | 300 × 220 × 180 mm11.81 × 8.66 × 7.09 in | United States | $ 99,500125 000 €88,260 £14,831,072 ¥ | Get a quote |
| Xact Metal | XM200C | SLM/DMLS | 127 × 127 × 127 mm5 × 5 × 5 in | United States | $ 110,000100 000 €97,574 £16,396,160 ¥ | Get a quote |
| Pollen AM | Pam Series MC | Extrusion | ⌀ 300 x 300 mm | – | $ 140,000135 000 €124,186 £20,867,840 ¥ | Get a quote |
| TRUMPF | TruPrint 1000 | SLM/DMLS | 100 × 100 × 100 mm3.94 × 3.94 × 3.94 in | – | $ 170,000170 000 €150,797 £25,339,520 ¥ | Get a quote |
| 3D Systems This brand is a certified partner from our network. | DMP Flex 100 | SLM/DMLS | 100 × 100 × 80 mm3.94 × 3.94 × 3.15 in | – | $ 245,000245 000 €217,325 £36,518,720 ¥ | Get a quote |
| EOS | EOS M 100 | SLM/DMLS | 100 × 100 × 95 mm3.94 × 3.94 × 3.74 in | Germany | $ 350,000350 000 €310,464 £52,169,600 ¥ | Get a quote |
| XJet | Carmel 700M | Material Jetting | 501 × 140 × 200 mm19.72 × 5.51 × 7.87 in | – | $ 599,000599 000 €531,337 £89,284,544 ¥ | Get a quote |
| Desktop Metal | Production System P-1 | Binder Jetting | 200 × 100 × 40 mm7.87 × 3.94 × 1.57 in | United States | upon request | Get a quote |
| Desktop Metal | Studio 2 | Extrusion | 300 × 200 × 200 mm11.81 × 7.87 × 7.87 in | United States | upon request | Get a quote |
| Digital Metal | DM P2500 | Material Jetting | 203 × 180 × 69 mm7. 99 × 7.09 × 2.72 in | – | upon request | Get a quote |
| Formalloy | L-Series | Directed Energy Deposition | 1000 × 1000 × 1000 mm39.37 × 39.37 × 39.37 in | United States | upon request | Get a quote |
| GE Additive | Arcam EBM Spectra L | EBM | ⌀ 350 x 430 mm | United States | upon request | Get a quote |
| GE Additive | M2 Series 5 | SLM/DMLS | 250 × 250 × 350 mm9.84 × 9.84 × 13.78 in | – | upon request | Get a quote |
| Renishaw | RenAM 500E | SLM/DMLS | 245 × 245 × 335 mm9.65 × 9.65 × 13.19 in | – | upon request | Get a quote |
| SLM Solutions | SLM 125 | SLM/DMLS | 125 × 125 × 75 mm4.92 × 4.92 × 2.95 in | Germany | upon request | Get a quote |
| SPEE3D | LIGHTSPEE3D | Material Jetting | 300 × 300 × 300 mm11. 81 × 11.81 × 11.81 in | – | upon request | Get a quote |
| TRIDITIVE | AMCELL | Extrusion | ⌀ 300 x 350 mm | Spain | upon request | Get a quote |
| Velo3D | Sapphire | SLM/DMLS | ⌀ 315 x 1000 mm | – | upon request | Get a quote |
Prices may vary by region, over time and do not include additional products or services (taxes, shipping, accessories, training, installation, …).
Main types of metal 3D printing technologies
The four main types of 3D metal printing technologies are:
- Metal Powder Bed Fusion 3D printing (SLS, SLM, DMP)
- Directed Energy Deposition (DED)
- Metal filament extrusion (FFF, FDM)
- Material Jetting and Binder Jetting
There are also some resin-based metal 3D printers, and metal sheet lamination 3D printers, but they are harder to come by.
It is not uncommon to see different acronyms and names for similar technologies. Each brand markets their own, proprietary methods.
Some metal 3D printer companies even use a mix of different technologies.
Here we provide a deeper look into each 3D metal printer from our list. They are grouped together according to their main 3D printing technology type (powder bed fusion, material/binder jetting, extrusion, and DED).
Extrusion-based metal 3D printer selection (FFF, FDM)
Extrusion consists of heating the material (filament) and pushing it through a nozzle. In the metal 3D printing case, the filament is generally made up of metal particles mixed into a binding agent.
After the part is 3D printed, the result is a raw object or part; it must go through several post-processing steps– such as debinding and sintering– to attain its final form.
Most extrusion-based metal 3D printing processes include these steps. The above illustration is sourced from Desktop Metal (Bound Metal Deposition™ process).
Desktop Metal’s Studio is an office-friendly, end-to-end metal 3D printing system. Aside from the printer, the Studio line also includes a debinding machine and a furnace for sintering. Indeed, parts 3D printed with this Desktop Metal 3D printer are “green”.
The Studio printer, with its proprietary Bound Metal Deposition technology, uses filament that is filled with small, metal rods. During debinding, the binding material (wax and polymer binders) is dissolved thanks to a proprietary liquid substance. The part is left porous, and must go in the furnace for its particles to fuse and densify the part.
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MarkForged is specialized in continuous fiber 3D printing, but also offers metal 3D printing with their Metal X system, featuring Atomic Diffusion Additive Manufacturing (ADAM) technology.
This MarkForged 3D printer extrudes metal-filled plastic filament to form the part, which must then be washed with a special debinding fluid (Wash-1 Station) and then sintered in a furnace (Sinter-1 or Sinter-2 MarkForged machines).
Available metal 3D printer filament includes various Steels (h23, A2, D2 tool steels, 316L stainless steel) as well as Inconel, Copper, and Titanium.
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Canada-based Rapidia offers an interesting and unique way to 3D print metal. They use a water-based metal paste, which eliminates the need for chemical debinding. The water evaporates during the 3D printing process, so the part only needs to go through the furnace in order to completely solidify and attain its final form.
Confirmed, available paste types include several Stainless Steels, Inconel, and a few ceramics. Copper, Tungsten Chrome Carbide, Titanium, and various other metals are in development.
The ExOne Metal Designlab, designed in collaboration with Rapidia, works on the same basis.
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Pollen AM is a French manufacturer that has been producing pellet 3D printers since 2013. Their Pam Series MC is a delta-style 3D printer (cylindrical build volume) that can print metals, ceramics, and thermoplastics.
It extrudes injection-molding-grade pellets instead of metal 3D printer filament, driving material costs down significantly. Pollen AM names their technology “Pellet Additive Manufacturing”.
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This machine was built with one goal: enable mass production 3D printing of metal parts 24/7. The AMCELL is fully automated, with auto feedstock control, environment control (temperatures, humidity, air filtering), and an ejection system fitted with a conveyor belt.
Rather than providing one, big build volume, the TRIDITIVE AMCELL boasts eight delta-style ø 220 x 330 mm build areas. Its eight “robots” deposit metal-infused filament to create 3D metal parts. TRIDITIVE states that resulting parts are similar to ones produced with traditional MIM (Metal Injection Molding) methods.
TRIDITIVE’s technology is called Automated Multimaterial Deposition®.
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Metal powder bed fusion 3D printer selection (SLS, SLM, DMP, and more)
At the moment, the most commonly used metal additive manufacturing technology is powder bed fusion 3D printing.
Simply put, the 3D printer creates objects out of a bed of powdered metal by using a powerful laser.
3D Systems, a historical actor on many 3D printing fronts, presents the DMP FLEX 100 as a fast, precise, and affordable metal 3D printer. It offers impressive part repeatability and surface finishes, of around 20 μm and 5 Ra μm respectively. DMP stands for Direct Metal Printing.
The printer comes with 3D Systems’ software 3DXpert All-in-One Software Solution for Metal Additive manufacturing. Their LaserForm metal 3D powders are certified.
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This compact metal 3D printer is destined for the production of small parts in small quantities. Its material portfolio is especially interesting for medical use cases, namely dental crowns and bridges. EOS certified metal powders include Cobalt-Chrome, Stainless Steel, and Titanium.
The EOS M100’s laser spot is precise enough to provide a great level of detail, backed by 200 W of powder.
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Originally a Swedish company, Arcam was acquired by GE Additive a few years ago. The Arcam EBM Spectra L is up to 20% faster than its predecessors and is able to reduce part costs by around 10%.
This metal 3D printer is dedicated to Titanium 3D printing, but Copper is in the pipeline as well. Its laser beam power is equal to 4.5 kW, partly explaining the printer’s high melting capacity and productivity. Common applications for this printer include orthopedic implants and parts for the aerospace industry.
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Concept Laser is the company behind GE Additive’s M2 Series 5. It offers an easy, optimized workflow, with a separate processing chamber and handling area that is integrated into the system. This closed-loop material system ensures a safe environment that is free of powder for the operator.
The M2 metal additive manufacturing solution is compatible with a range of metals, from Stainless Steels to Aluminum, Nickel, Titanium, and Cobalt-Chrome.
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The RenAM 500E is Renishaw’s entry-level metal additive manufacturing solution. It offers a relatively large build volume and powder can be handled via a dedicated glove box to avoid powder from getting free.
This system is also equipped with an oxygen sensor and a proprietary emission-filtering system branded SafeChange™.
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Officially established in 2006, SLM Solutions has been a historical player in the powder bed fusion industry for many years. The SLM 125 boasts an open software architecture that allows users to tweak the system’s parameters according to specific use cases, materials, and general needs.
Options such as laser monitoring and melt pool monitoring are available for businesses that require full transparency and control over their production series.
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The TruPrint 1000 is TRUMPF’s most compact metal 3D printing system, with a 100mm-tall cylindrical build volume.
It is suitable for the production of small parts and prototypes, and even small production series when equipped with the multilaser option that increases the printer’s speed.
This metal 3D printer can be operated remotely via a tablet application, which also gives access to its onboard camera stream.
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The Velo3D Sapphire is a high-volume metal 3D printer from the US designed for production series. This metal 3D printer features Velo3D’s Intelligent Fusion technology to allow for complex geometries and 0° overhangs.
The system is also equipped with a range of metrology sensors that measure each and every layer that is 3D printed.
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The XM200C is Xact Metal’s entry-level metal 3D printing solution. It is suitable for both research purposes and small production series. The XM200C benefits from a proprietary Xact Core gantry system for precise movements with a fusing speed of up to 500 mm/s.
Xact Metal offers their own materials, branded Xact Powder, including various Stainless Steels, Super Alloys, Tooling Steels, Aluminum, Titanium, Bronze, and Copper. Advanced users are able to use their own metal powders if needed.
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Metal material jetting and binder jetting 3D printers
Material jetting 3D printers are equipped with various inkjet printheads (somewhat similar to 2D printing) that jet material onto a surface. The material then hardens, and another layer of “metal ink” is jetted on top.
Binder jetting is a similar process, but it is a binding agent that is jetted atop a layer of powder.
The Production System by Desktop Metal was designed for mass production. It is advertised by Desktop Metal as being a fast, cost-effective metal additive manufacturing solution, with a cost per part up to 20 times lower than with other metal 3D printing systems.
This Desktop Metal 3D printer is equipped with over 16,000 nozzles that are mounted onto a “print bar” that recoats the build plate with powder at the same time, hence explaining the technology’s name: Single Pass Jetting™.-kupit-v-soin-store.ru-3.png)
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Digital Metal, a Höganäs Group company, creates incredibly detailed metal parts with their DM P2500 system. It is able to print 3D metal parts with an accuracy as high as 0.001mm (1µ), and with a medical-grade surface quality of around 0.006mm (6µ).
Another interesting feat to point out is that almost 100% of leftover powder can be recycled for future prints. This metal AM machine is able to churn out serial production series efficiently and reliably; one of the company’s first DM P2500 printers has been running 24/7 since 2013, according to Digital Metal.
The Digital Metal DM P2500 is a certified metal 3D printer (CE and UL) that is compatible with certified metal materials (ISO 22068).
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Australian manufacturer SPEE3D has developed an impressively fast metal 3D printing technology called Supersonic Deposition. The technology is based on metal cold spray, using compressed air to “jet” metal powder through a nozzle at high speeds.
This enables the LightSPEE3D to 3D print at up to 100 grams per minute and with a range of metals including copper.
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XJet developed an impressive, proprietary jetting technology they call NanoParticle Jetting™. This inkjet method disperses millions of tiny droplets that contain nanoparticles of solid metal. The liquid material comes in cartridges that are easy to insert into the printer.
After being printed, the metal parts must go through support removal and sintering processes to attain their final form.
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DED: Directed Energy Deposition metal additive manufacturing systems
Directed Energy Deposition (DED) is comparable to filament extrusion. The metal material is pushed through a special nozzle, like with FFF/FDM, but a powerful laser beam solidifies the material at its deposition point.
Formalloy produces a range of metal DED 3D printers with up to 5 axes of motion.
They can be used to produce metal parts but also to repair or clad existing parts.
Different laser wavelengths are available, as well as different build volumes: 200 x 200 x 200 mm, 500 x 500 x 500 mm, and 1000 x 1000 x 1000 mm. Metal 3D printers from Formalloy can be customized depending on company requirements.
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Alternative metal 3D printers and special mentions
Hybrid metal manufacturing systems
Some manufacturers are specialized in hybrid metal manufacturing systems. They combine both subtractive and additive manufacturing methods, often with robotic arms that are able to move on more than three axes.
Some of the biggest actors on the hybrid metal AM system market are:
- Gefertec (Germany)
- DMG Mori (Germany)
- Matsuura (Japan)
- Sodick (United States)
XXL-sized metal 3D printers for industrial production
For those that require very large metal parts, there are several huge, industrial machines that offer gigantic build volumes for industrial production.
To name a few:
- Sciaky EBAM 300
- Titomic TKF1000
- ADC Aeroswift
- ADIRA AddCreator
- Fabrisonic SonicLayer 4000
- ExOne X1 160PRO
- InssTek MX-600
- BeAM Modulo 400
- Optomec Lens CS 600
- Additive Industries MetalFAB1
Metal 3D printers from China
There has recently been a lot of growth in the metal 3D printer market in Asia, and more specifically in China. Some Chinese brands have been upping their game in that respect, providing industrial-grade metal 3D printing options:
- Farsoon
- ZRapid Tech
- Shining 3D
- Wiiboox
However, we feel that they are not yet playing in the same league as the 3D printers from our main selection, mostly due to a lack of distribution networks, after-sales service and training, and other factors which tend to matter when considering them together as a whole.
R&D metal 3D printers for labs
In certain cases, metal 3D printers are used for research purposes to develop and test new materials.
There are a few machines that are specifically designed for this:
- Open Additive PANDA-6”
- Freemelt ONE
- Sharebot metalONE
Pros and cons of metal 3D additive manufacturing
Benefits of 3D printing metal parts
- On-demand production: Metal additive manufacturing offers more flexibility and control over the production line.
- Complex designs made possible: With 3D printing technology, it is possible to create highly detailed and intricate parts that would have to be broken down into several pieces with traditional methods.
- Waste reduction: Compared to CNC milling, for example, metal AM produces much less waste as it only consumes the material needed for a certain part. This is more true for extrusion-based methods than it is for powder-based methods, where it isn’t always possible to re-use 100% of unsintered or unbinded material.
- Lighter parts: Whereas metal parts are usually completely solid infill-wise with other methods, 3D printing allows parts to be more or less hollow without undermining their strength and resistance.
- Cost-effectiveness: All the above benefits of metal 3D printing can inherently reduce costs per part, although high metal 3D printer prices do represent a significant entry barrier. Reaching a positive return on investment can take a while depending on your throughput.
Limits of metal 3D printing
- Metal 3D printing prices: Metal AM systems are still quite expensive, as are metal powders and metal filaments. There are hidden costs, too (e.g. energy consumption, learning curve, etc.).
- Environmental constraints and safety precautions: Most metal 3D printers have a large footprint and require specific operating environments with controlled temperatures, hygrometry, and more.
- Post-processing: In many cases it is necessary for parts to be post-processed, whether it’s debinding and sintering or finishing touches for surface quality.
- Physical properties: It can be difficult to achieve the same physical properties that traditionally manufactured metal parts have. There are a number of factors (e.g. anisotropy) to take into account during the design process and file preparation before even trying to 3D print a certain part.
Metal 3D printing materials
Which metals can you 3D print?
A growing number of metals and metal alloys can be 3D printed. These are the main ones:
- Aluminum
- Titanium
- Nickel, Inconel
- Copper
- Bronze
- Cobalt, Cobalt-Chrome
- Steels (tooling, maraging, stainless)
- Precious metals (gold, silver, platinum)
Which metal 3D printing material formats are available?
Metal 3D printing material can be found in various formats, catering to different metal 3D printing methods.
The most common are:
- Powder
- Wire
- Filament
It is also possible to find metal 3D printing resin as well as metal sheets for lamination-based 3D printers.
Metal 3D printer price: how much does a metal 3D printer cost?
Industrial metal 3D printer prices generally range from about $30,000 to over one million dollars for the most premium, industrial-grade metal additive manufacturing systems.
Additional costs to consider are the materials for metal 3D printing, which can cost a few hundred USD/kg, as well as costs linked to post-processing (tools, time, etc.).
Applications for metal AM systems
There are thousands of possibilities and use cases for metal 3D printing in a wide range of industries. A few industries have been incrementally using metal AM:
- Aerospace
- Automotive
- Medical
Whether it’s for tooling, replacement parts, or final products, many businesses can benefit from metal 3D printing.
However, metal additive manufacturing isn’t necessarily beneficial for every single metal part. Although some metal 3D printing systems have a relative capacity for serial production, it is generally cheaper to keep using traditional methods for simple parts.
For cases where complex geometries, rapid prototyping, and mass customization are required, metal AM is convenient and efficient.
Metal 3D printing services: order 3D metal parts online
For professionals with limited office space and human resources, low budgets, and/or few needs of custom parts and prototypes, metal 3D printing services can be an ideal solution.
These additive manufacturing service companies own a variety of high-quality 3D printers with different technologies, and their professionals are experts in 3D printing. It is possible to order metal 3D parts on-demand, without acquiring a 3D printer or having to buy a certain material for one-time use.
Here are some of the most trusted 3D printing service providers that offer metal printing services:
- Sculpteo
- Shapeways
- Hubs (ex 3D Hubs)
- Stratasys
- i.materialise
- Protolabs
Metal 3D printing technologies and acronyms
Many manufacturers develop proprietary variations of existing technologies and label them their own registered names:
- Powder Bed Fusion (PBF): DMLS (Direct Metal Laser Sintering), DMP (Direct Metal Printing), LaserCUSING, LBM (Laser Beam Melting), LMF (Laser Metal Fusion), SLS (Selective Laser Sintering), SLM (Selective Laser Melting)
- Directed Energy Deposition (DED): DMT (Direct Metal Tooling), EBAM (Electron Beam Additive Manufacturing), EBM (Electron Beam Melting), LENS (Laser Engineered Net Shaping), LMD (Laser Metal Deposition)
- Metal Material Jetting (MJ) or Binder Jetting (BJ): Magnet-o-Jet, Nanoparticle Jetting, SPJ (Single Pass Jetting), Metal Jet
- Metal filament extrusion/Fused Filament Fabrication (FFF): ADAM (Atomic Diffusion Additive Manufacturing), CEM (Composite Extrusion Modeling), FDM (Fused Deposition Modeling), FFD (Fused Feedstock Deposition), FMP (Filament Metal Printing), BMD (Bound Metal Deposition), MIM (Metal Injection Molding)
- Lamination: SL (Sheet Lamination), UAM (Ultrasonic Additive Manufacturing)
- Metal resin 3D printing: DLP (Digital Light Processing), FluidFM, SLA (Stereolithography)
Metal 3D printing FAQ
Is 3D printed metal strong?
Metal 3D printed parts can be as strong (or even stronger) as metal parts created with traditional manufacturing processes such as casting.
The part’s strength will, however, depend on the metal AM method used and the conditions in which it is 3D printed.
When was 3D metal printing invented?
Metal 3D printing became possible in the 1990s with the development of Selective Laser Melting technology. However, 3D metal printing only started to gain traction and public interest from around 2010 onwards.
How does metal 3D printing work?
There are several ways to 3D print metal. Layers of metal filament can be deposited one after the other, producing a green part that must later go through debinding and sintering steps. It is also possible to fuse metal powder particles together with a laser, or with an inkjet printhead that deposits drops of binding material onto the powder.
Precise metal 3D printing on order in Sprint 3D
Metal 3D printing - additive manufacturing of metal products, which is rightfully one of the most promising and rapidly developing areas in 3D printing as such.
The technology itself originates from the conventional sintering of materials used in powder metallurgy. But now it has become more perfect, accurate and fast. And today SPRINT3D offers you metal printing on 3 D printer on really favorable terms. But first, a little information about the production process itself and its capabilities.
Selective Laser Fusion Technology
SLM or Selective Fusion Technology is a type of direct metal printing that achieves a density of 99.5%. The difference is especially noticeable when compared with models obtained by conventional casting. This indicator is achieved due to the introduction of the latest technologies in the hardware part:
- The use of special rollers for compacting powders and, as a result, the possibility of using powders with a particle size of 5 microns.
- Bulk density increase to help compact end products.
- Creates a rarefied atmosphere of inert gases, which ensures maximum purity of the material, no oxidation, and eliminates the risk of introducing third-party chemical compounds into the composition.
But most importantly, the modern 3 D Metal Printer makes it easy to customize the configuration for printing with a specific metal powder. Thus, even with inexpensive material, you can get a first-class result. But only if you use high-quality modern equipment. And here we are ready to surprise you too!
Metal 3D printing B SPRINT 3D
3D printing with own 3D printers
The largest working area is 280x280x350 mm
layer thickness up to 15 micron
3D with various types of metals
Delivery throughout Russia and CIS countries
installations for 3 D metal print, which we use
Production quality is a key requirement that we set ourselves. Therefore, in our work we use only professional equipment with wide possibilities for metal printing. Let's take a closer look at each of the production units. nine0009
Production unit SLM 280HL
SLM 280HL is a development of the German company SLM Solutions GmbH, which uses the technology of layer-by-layer laser melting of powder metal materials.
The installation is equipped with a large working chamber and allows you to create 3D objects with dimensions of 280x280x350 mm. Among the main advantages of printing with this unit are:
- Small minimum thickness of the applied layer - 20 microns.
- Filling the working chamber with an inert gas, which allows you to work with various reactive metals.
- Print speed up to 35 cm/hour.
- Construction layer thickness – 30 and 50 µm.
- Power - 400 W.
A special highlight is the patented powder feed system, which delivers significantly faster print speeds than most production machines in the same price range. We use the following materials in production:
- Stainless steel (domestic 07X18H12M2 (Polema), 12X18H10T and imported 316L).
- Tool steel (imported 1.2709).
- Heat-resistant alloys 08KhN53BMTYu (similar to Inconel 718, produced by Polem) and EP 741 (produced by VILS).
- Cobalt Chrome (COCR)
The SLM 280HL 3D printer can be used to create all kinds of metal components, prototypes and end products. If necessary, we can provide small-scale production. nine0009
ProX 100 production unit
ProX 100 is a compact 3 D metal printing unit developed by the American company 3D Systems. It uses direct laser sintering technology, which ensures high speed and precision of production. Among the main characteristics it is worth highlighting:
- The size of the working chamber is 100x100x80 mm.
- Construction layer thickness – 20 and 30 µm. nine0021
- Power - 50 W.
ProX 100 allows you to create prototypes that can not be developed by standard methods, provides short lead times, guarantees the absence of material porosity and high part density. In addition, we note the standardized quality of all products, regardless of their structure.
At the moment, the model is actively used in dentistry when creating high-precision prostheses, but has found wide application in other industries:
- Manufacture of engines and their individual parts.
- Development of medical equipment.
- Printing jewelry and even contemporary art.
In printing, we use an alloy of cobalt-chromium KX28M6 (manufactured by Polem), originally developed for additive technologies when creating endoprostheses.
Metal 3D printing - current application
Many experts argue that 3D printing as such has not yet fully revealed its potential. For example, Elon Musk plans to use technology in the colonization of Mars to build administrative and residential buildings, equipment and machinery right on the spot. And this is quite real, because already now the technology of three-dimensional metal printing is actively used in various industries: The high precision of production and relatively affordable price have made 3D printing very relevant in this industry.
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And this is only a small part of what can be created on modern equipment. Almost all metal products that you need can be created using metal 3D printing technology. And if this service is relevant for you, contact SPRINT3D. We will undertake work of any complexity and volume. And most importantly - we will provide first-class results!
The future is here!
You may be interested in
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? nine0009
Let's see how a 3D printed steel part is revolutionizing manufacturing and opening doors 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. nine0013 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. nine0009
Parts printed from steel are used in the aerospace industry, for the military, and also, 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.
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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. nine0009
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.
nine0009 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. nine0009
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.
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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.
Types of steel for 3D printing
Metal powder is the most used metal material for 3D printing (Source: GKN Additive)There are thousands of different grades of steels 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:
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Stainless steel (316L, 304L , 17-4PH, 15-5PH, 420, 254, Ph2, GP1, 630, 410).
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Tool steel (D2, M2, h23, h21, MS1, 1.2709).
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Low alloy steel (4140).
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Structural alloyed (20MnCr5).
Recently, unique alloys have been developed specifically for 3D printing, designed to solve the problems that occur with classical production methods.
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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 achieve increased corrosion resistance while being easy to machine and polish. nine0009
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. nine0009
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. nine0009 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. nine0009
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 Ultrafuse 316L stainless steel filament produces finished parts with material properties that the company claims are comparable to injection molded metal parts. nine0009 (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.
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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 (Source: Desktop Metal)Similar to FDM, 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. nine0009
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. nine0009
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. nine0009
Laser powder sintering.
Laser powder sintering technology uses one or more lasers to melt powdered metal layer by layer into a desired shape. (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. nine0009
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.-kupit-v-soin-store.ru-4.png)
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. nine0009
Binder Jetting
Binder Jetting 3D printing technology uses powdered metal 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 parts made by metal injection molding. nine0009
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. nine0009
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 its 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.
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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. nine0009
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. nine0009
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 post-accident repairs because high-strength steel substrates in automobiles can be susceptible to thermal repair methods such as welding. nine0009
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. nine0009
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. nine0009
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).
