Can you use metal in a 3d printer

Can 3D Printing Use Metal? (Everything You Need To Know)

Yes, it is possible to 3D print items from metal. There are several manufacturing processes which fall under the heading of metal additive manufacturing, but this article concentrates on those which use layers of metal powder to build up and form complex structures that may be difficult to create with other techniques.

The metal 3D printing process involves sintering or melting metal powders directly, or combining them with a second material to allow delivery through a nozzle. It is used for both rapid prototyping and finished production parts for aerospace, mechanical engineering, tooling and more.

Click the links below to skip to the section in the guide:

What metals can be used in 3d printing?
What metals cannot be 3d printed?
What processes can be used to 3D print metals?
Other techniques
Advantages and disadvantages
What is the purpose of 3D metal printing?
Is it expensive?
Conclusion

A wide range of different metals can be used in powder form to manufacture parts through 3D printing. Titanium, steel, stainless steel, aluminium, copper, cobalt chrome, titanium, tungsten and nickel-based alloys are all available in powdered form for 3D printing, as are precious metals like gold, platinum, palladium and silver.

These different metals offer various properties, making them suitable for a range of applications. For example, stainless steel provides excellent corrosion resistance, making it ideal for printing pipes, valves and steam turbine parts.

Theoretically, any metal can be used for 3D printing if it is available as a suitable powder. However, materials that burn rather than melt at high temperatures cannot be processed safely by sintering or melting, but can be used when extruded through a nozzle for 3D printing. Wood, cloth and paper cannot be 3D printed using these processes.

It is also possible to use sintering (forming inside a mould at high temperature and extremely high pressure) to create solid items from metal powders and, in the case of those metals with very high melting points, sintering is the only reliable method to manufacture items from these materials.

As hinted above, there are several technologies for 3D printing metals. Powder bed fusion techniques, which include Direct Metal Laser Sintering (DMLS), SLM (Selective Laser Melting) and EBM (Electron Beam Melting), are the more widely used techniques for metal additive manufacturing:

Direct Metal Laser Sintering (DMLS)

This commonly used method uses a laser to sinter metal powder layer-by-layer to form an object. The process does not actually melt the metal and is used for prototyping and manufacturing finished parts including medical devices and instruments.

Selective Laser Melting (SLM)

This process involves using a laser to melt the material where required within a layer of powder in an inert gas environment. This proceeds layer by layer for creating objects with similar parameters to those produced with casting. SLM is often used to manufacture parts from aluminium and titanium, including those for the medical, automotive and aerospace industries.

Electron Beam Melting (EBM)

This process is similar to SLM, except an electron beam is used to melt the material rather than a laser. EBM is perceived as being faster and more precise than SLM and is often used to manufacture items from cobalt and titanium. EBM is widely used by the aerospace industry for items including engine components.

There are other techniques that can or have been used for 3D printing metals, although these are not as widely used as DMLS, SLM or EBM:

Laser Metal Deposition (LMD)

LMD is used in the aerospace, automotive and medical industries, creating objects by depositing heated metal on a metallic substrate layer-by-layer. LMD allows different materials to be used to build an object and is faster than other methods

Selective Laser Sintering (SLS)

Similar to DMLS, this process also uses a laser to sinter powdered materials. It has been used to manufacture items from a wide range of materials, including metal. However, these days it is mostly used for sintering plastics, such as polyamide and nylon

Binder Jetting

This process uses a special liquid to bind the powder material and is less expensive than DMLS, SLM or EBM. The accuracy and strength afforded by this process are not perfect and post-processing is often required. Hot isostatic pressing can be used to improve the strength and solidity of the finished object, but this increases the costs. Binder jetting is typically used for the manufacture of large scale and complex prototypes

Metal Injection Moulding

This combination of injection moulding and 3D printing is widely used for making small components in industries including medical and defence. The process works by mixing metal powder with thermoplastic and wax binders. This mix is heated until the binder melts and covers the powder, which is then granulated into pellets. These pellets are heated and injected into a cavity to form the object before the binder material is removed, usually via solvent extraction. The part is then sintered, evaporating any remaining binder and compressing the object into a dense solid. The object can then be finished as required.

There are a number of benefits and drawbacks associated with 3D metal printing, as follows:

Advantages

Easy to manufacture items with complex shapes faster than traditional manufacturing methods
Cheaper than many conventional manufacturing methods for some parts
Capable of producing precise and highly detailed objects
Because details can be included at time of assembly, it can save time and money compared to more traditional methods of manufacture
Complicated forms can be created to create lighter objects without sacrificing strength, making 3D metal printing ideal for automotive, aerospace and space applications
Very little material wastage
Multiple parts of a complicated assembly can be combined into a single component, reducing part count and assembly costs

Disadvantages

Slow to produce parts designed for traditional manufacturing, making high volume production uncompetitive on cost alone
Powdered metal materials are more expensive than non-powdered metals (e. g. billet or bar)
Metal 3D printers can be expensive
Surface finishing and post-processing of 3D printed parts may be required
Offers lower precision and tolerance than specialised CNC machining
Heat treatment may be needed to reduce inner stresses in a 3D printed item, or achieve maximum strength in the metal
Design of 3D metal parts can be complex and require the services of professional CAD engineers
The size of parts is limited by the build volume of the 3D printer

The advantages and disadvantages of the process provide an insight into the purpose of 3D printing in metal, showing that it is well suited to manufacturing relatively small, complex parts, including prototypes. It can also facilitate tooling for conventional manufacturing technologies, lowering costs and reducing lead times.

By combining the flexibility of 3D printing with the mechanical properties of metal, this technology has found uses across industry, from inserts with cooling channels through lightweight structures for the aerospace industry, to complex parts to be used in highly demanding environments. Typical uses include fully functional prototyping, creating production tools, tooling for moulds or inserts, housings, ductwork, heat exchangers and heatsinks.

Of course, different metals lend themselves to the printing of different objects, for example:

Stainless Steel: Perfect for objects that will come into contact with corrosive liquids, water or steam, due to the superb corrosion resistance
Bronze: Pump impellors and marine propellers, fixtures and more decorative items, such as vases
Gold: Can be used to print jewellery
Nickel: Can be used to print turbine engine parts or even coins
Aluminum: Ideal for metal objects, especially where lightweighting is required, such as with airframe parts
Titanium: Capable of producing very strong, accurate parts such as medical implants (e.g. hip joints) and other solid fixtures and objects

Different 3D printing techniques use different solutions for industry with different materials and complexity, meaning that the cost of 3D printing in metal can vary substantially. However, most of the cost comes from the 3D printing machines, which can be a large proportion of overall costs for a production run, alongside labour, materials, preparation and post-processing. The requirement for high-quality powdered materials also adds to the cost of 3D metal printing as they are more expensive than non-powdered metals in the same quantities.

As mentioned, printer prices can be high, with costs of several or even hundreds of thousands of pounds, although these prices are comparable to a high quality CNC machine tool of a similar size. As technology and the market size improves, it is expected that the price of 3D printing machines will decrease.

As well as the cost of materials and the printer, there are design costs for the objects to be created. This can involve the need to buy specialist software or hire the services of CAD engineers with specialist knowledge of 3D printing. There are, of course, other labour costs for the operation and maintenance of the machines.

Finally, there are costs associated with post processing of printed parts. This can include cleaning, heat treatment, the removal of support structures and applying coatings to the surface.

3D printing with metal, or additive manufacturing, allows for parts to be made with almost the same strength as regular metal objects.

While it can be expensive and is not well-suited to replacing conventional manufacturing for high volume production of standard items, it is ideal for making smaller, complex items. 3D printing with metals also assists with lightweighting for parts used in industries including aerospace and automotive.

New filament means you can print metal on any 3D printer

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You might want to sit down, because this one is exciting. The Virtual Foundry has just launched Filamet™, a new metal infused filament that makes any FDM 3D Printer, a 3D Metal Printer!

Yes, really…

We just got used to the fact that only high-end printers could manage metal and most mortal makers would have to make do with simple plastics. That just changed, you can now print Copper and Bronze on any 3d Printer.

This new filament from the Wisconsin-based company could literally be a game changer, disrupting the current course of 3D Printed Metal. They’ve launched with copper and bronze, but you can expect to see more metals in the near future.

More than just metal.

The Virtual Foundry’s patented process works not only with metal,but they will follow up with 3d printable Glass and Ceramic products over the next 6 months. So maybe you don’t have to upgrade your 3D printer after all and even the most basic desktop unit could become a complete manufacturing facility thanks to this quantum leap in material science.

How does it work? It’s basically a highly infused plastic, just enough plastic to get it through your current printer. Currently this is a mere 11.5%, an amount considered below the theoretical limit only a year ago. The 88.5% of mass that remains is high purity metal powder. The prints can then be simply polished, or more interestingly be post-processed to remove the small amount of plastic. The resulting product is 99+% pure metal, which is as close to pure as many of us will ever need. The Virtual Foundry says they continue to improve the process and expect future versions to be closer to only 8% plastic.

Another great Kickstarter success story?

This project surfaced on Kickstarter last year, where it raised 135% of the target funding. The Virtual Foundry, though, has been on a mission to bring metal production to our desktops since before 3D printing was even an option. It worked with cold-casting and electro forming in the old days, but now technology has caught up and 3D printing looks to have given them the answer.

We haven’t got our hands on the finished product just yet. But the big launch at the Hubble Auditorium at Lockheed-Martin suggests that the team has really cracked the code.

“Printer manufacturers have struggled for years to bring metal printing down into the price range of the average individual or small business,” said Bradley Woods, the man behind this technical breakthrough. “Filamet™ takes the opposite strategy. Rather than bring the high-end down, it simply expands the capabilities of current 3D printers.”

“We expect materials to account for a large portion of near-term product innovation in the 3D printing market. Our company offers an immediate solution to producing real and useful metal prints on the desktop 3D printer that you already own.”

Professionalise your home printer

This filament could turn your desktop printer into a rival for the serious commercial machines and could even prove to be better. That’s because metal printers are notoriously slow and a large printer can actually take 48 hours to produce a single print.

So while the end result might be spectacular, it simply might not suit your workflow even if you could afford to have one in your home workshop.

Consumer printers are designed with the average user in mind, so they offer a realistic compromise of price, resolution and speed. With the addition of this metallic filament, then your home 3D printer could become a real manufacturing weapon. We can suddenly make copper and bronze statues and parts without access to a kiln and that could be a maker’s revolution on its own.

Prints can take less than five hours with a consumer printer and this new material is even big news for big business.

Companies are into this too

The technology has attracted big names like Calvin Klein and a company that wants to license the technology to fabricate consumable parts for its facility that 3D prints Uranium fuel cells for nuclear reactors. The technology works with any 3D printer,which means that even commercial companies with several printer scan now opt to use their simpler units for faster, cheaper production.

This opens up so many new avenues and the science itself could be a launchpad for other companies to create their own innovations. We’ve often said that the biggest step forward will come from the materials, but even we didn’t see a company turning today’s printers into complete metal, glass and ceramic production facilities.
We can’t wait to see the products in action and to test this filament for ourselves. If it turns out to be half as good as the claims then it has the capacity to change everything.

http://www.theVirtualFoundry.com & [email protected]

More images at http://www.thevirtualfoundry.com/showcase/

Tags fdmfff Filamet metallic

Nick Hall

Nick is a freelance journalist who has covered the cut and thrust of Formula One and the technical side of the supercar industry for the likes of The Sunday Times, Automobile and Penthouse on these shores, Tatler and The National in Dubai. After finally driving an F1 car there was nowhere left to go, so now he is here!

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

Metal 3D printing. Additive technologies.

SLM or DMLS: what's the difference?

Hello everyone, Friends! 3DTool is with you!

BLT metal 3D printer catalog

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

The differences between SLM and DMLS come down to the basics of the particle bonding process: SLM uses metal powders with a single melting point and completely melts the particles, while in DMLS the powder consists of materials with variable melting points. nine0014

Specifically:
SLM produces single metal parts while DMLS produces metal alloy parts.
Both SLM and DMLS technologies are used in industry to create final engineering products. In this article, we will use the term "metal 3D printing" to summarize the 2 technologies. We will also describe the main mechanisms of the manufacturing process that are necessary for engineers to understand the advantages and disadvantages of these technologies. nine0002 There are other manufacturing processes for producing dense metal parts, such as electron beam melting (EBM) and ultrasonic additive manufacturing (UAM). Their availability and distribution is rather limited, so they will not be presented in this article.

How 3D printing with SLM or DMLS metal works.

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

1. The printing chamber is first filled with an inert gas (such as argon) to minimize the oxidation of the metal powder. It then heats up to the optimum operating temperature. nine0002 2. A layer of powder is spread over the platform, a powerful laser makes passes along a predetermined path in the program, fusing the metal particles together and creating the next layer.
3. When the sintering process is completed, the platform moves down 1 layer. Next, another thin layer of metal powder is applied. The process is repeated until the entire model is printed.

When the printing process is completed, the metal powder already has strong bonds in the structure. Unlike the SLS process, parts are attached to the platform via support structures. The support in metal 3D printing is created from the same material as the base part. This condition is necessary to reduce deformations that may occur due to high processing temperatures. nine0002 When the 3D printer's chamber cools down to room temperature, excess powder is removed manually, such as with a brush. The parts are then typically heat treated while they are still attached to the platform. This is done to relieve any residual stresses. They can then be further processed. The removal of the part from the platform occurs by means of sawing.

Scheme of operation of a 3D printer for metal.

In SLM and DMLS, almost all process parameters are set by the manufacturer. The layer height used in metal 3D printing varies from 20 to 50 microns and depends on the properties of the metal powder (fluidity, particle size distribution, shape, etc.). nine0002 The basic size of the print area on metal 3D printers is 200 x 150 x 150 mm, but there are also larger sizes of the working area. Printing accuracy is from 50 - 100 microns. As of 2020, metal 3D printers start at $150,000. For example, our company offers 3D metal printers from BLT.
metal 3D printers can be used for small batch production, but the 3D printing capabilities of such systems are more like those of mass production on FDM or SLA machines. nine0002 The metal powder in SLM and DMLS is recyclable: typically less than 5% is consumed. After each impression, the unused powder is collected and sieved, and then topped up with fresh material to the level required for the next production.
Waste in metal printing, are supports (support structures, without which it will not be possible to achieve a successful result). With too much support on the manufactured parts, the cost of the entire production will increase accordingly. nine0002

Adhesion between coats.

3D metal printing on BLT 3D printers

SLM and DMLS metal parts have almost isotropic mechanical and thermal properties. They are hard and have very little internal porosity (less than 0.2% in 3D printed condition and virtually non-existent after processing).
Metal printed parts have higher strength and hardness and are often more flexible than traditionally made parts. However, such metal becomes “tired” faster. nine0014

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

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

Supports in metal 3D printing perform 3 functions:

• They form the basis for creating the first layer of the part.
• They secure the part to the platform and prevent it from deforming.
• They act as a heat sink, removing heat from the model. nine0014

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

Since the cost of metal printing is very high, software simulations are often used to predict how a part will behave during processing. These topology optimization algorithms are otherwise used not only to increase mechanical performance and create lightweight parts, but also to minimize the need for supports and the likelihood of part distortion. nine0014

Hollow sections and lightweight structures.

An example of printing on a BLT 3D printer

Unlike polymer powder melt processes such as SLS, large hollow sections are not typically used in metal printing as the support would be very difficult to remove, if at all possible.
For internal channels larger than Ø 8 mm, it is recommended to use diamond or teardrop cross-sections instead of round ones, as they do not require support. More detailed recommendations on the design of SLM and DMLS can be found in other articles on this topic. nine0014

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

The use of a lattice structure is a common strategy in metal 3D printing to reduce part weight. Topology optimization algorithms can also help design organic lightweight shapes. nine0014

Consumables for 3D metal printing.

SLM and DMLS technologies can produce parts from a wide range of metals and metal alloys, including aluminum, stainless steel, titanium, cobalt, chromium and inconel. These materials meet the needs of most industrial applications, from aerospace to medical applications. Precious metals such as gold, platinum, palladium and silver can also be processed, but their use is of a minor nature and is mainly limited to jewelry making. nine0014

The cost of metal powder is very high. For example, a kilogram of 316 stainless steel powder costs approximately $350-$450. For this reason, minimizing part volume and the need for supports is key to maintaining optimal manufacturing cost.
The main advantage of metal 3D printing is its compatibility with high-strength materials such as nickel or cobalt-chromium superalloys, which are very difficult to machine with traditional methods. Significant cost and time savings can be achieved by using metal 3D printing to create a near-clean shape part. Subsequently, such a part can be processed to a very high surface quality. nine0002

Metal post-processing.

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

CNC machining can be used for critical features (such as holes or threads). Sandblasting, plating, polishing, and micro-machining can improve the surface quality and fatigue strength of a metal printed part. nine0014

Advantages and disadvantages of metal 3D printing.

Pros:

1. Metal 3D printing can be used to make complex custom parts, with geometries that traditional manufacturing methods cannot provide.
2. Metal 3D printed parts can be optimized to increase their performance with minimal weight.
3. Metal 3D printed parts have excellent physical properties, metal 3D printers can print a wide range of metals and alloys. Includes difficult-to-machine materials and metal superalloys. nine0014

Cons:

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

Conclusions.

• Metal 3D printing is most suitable for complex, one-piece parts that are difficult or very expensive to manufacture using traditional methods, such as CNC.
• Reducing the need for building supports, will significantly reduce the cost of printing with metal. nine0002 • 3D printed metal parts have excellent mechanical properties and can be made from a wide range of engineering materials, including superalloys.

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

Catalog of 3D printers for metal BLT

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

• By email: [email protected]

• By phone: 8(800)775-86-69

• Or on our website: http://3dtool.ru

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technologies, equipment, materials and new opportunities

There is no hotter trend in 3D printing today than metal. We will talk about metal printing at home, how it is done on an industrial scale, about technologies, applications, printers, processes, prices and materials. Over the past few years, 3D metal printing has been actively gaining popularity. And this is quite natural: each material offers a unique combination of practical and aesthetic qualities, can be suitable for a wide range of products, prototypes, miniatures, decorations, functional details and even kitchen utensils. The reason metal 3D printing has become so popular is because the printed objects can be mass-produced. nine0014

In fact, some of the printed parts are just as good (if not better) than those made by traditional methods. In traditional production, working with plastic and metal can be quite wasteful - there is a lot of waste, a lot of excess material is used. When an aircraft manufacturer makes metal parts, up to 90% of the material is simply cut off. 3D printed metal parts require less energy and waste is reduced to a minimum. It is also important that the final 3D printed product is up to 60% lighter than a traditional part. Billions of dollars could be saved in the aviation industry alone—mainly through weight savings and fuel savings. So, what do we need to know about metal 3D printing? nine0014

3D metal printing at home

If you want to make objects at home that will look like metal, your best bet is to look at metalized PLA filaments (Photo: colorFabb)

Where to start if you want to print metal objects at home? Given the extreme heat required for true metal 3D printing, a conventional FDM 3D printer will not be able to do this. nine0014

It is unlikely that in this decade it will be possible to print with liquid metal at home. Until 2020, you probably will not have a printer specialized for this purpose at home. But in a few years, as nanotechnology advances, we may see significant developments in new applications. This can be 3D printed with conductive silver, which will emit in much the same way as it does in 2D home printers. It will even be possible to mix different materials like plastic and metal in one object. nine0014

Materials for Metal 3D Printing at Home

Even though you can't print actual metal objects at home, you can turn to plastic filament that has been infused with metal powders. Bestfilament, ColorFabb, ProtoPasta and TreeD Filaments offer interesting metal-PLA composite filaments. These filaments, containing a significant percentage of metal powders, remain pliable enough to be printed at low temperatures (200 to 300 Celsius) on virtually any 3D printer. At the same time, they contain enough metal to make the final object look, feel, and even weigh like metal. Iron-based filaments even rust under certain conditions. nine0014

But you can go further. Typically, up to 50 percent metal powder is added to 3D printing filament. Dutch company Formfutura says they have achieved 85 percent metal powder with 15 percent PLA. These filaments are called MetalFil Ancient Bronze and Metalfil Classic Copper. They can be printed even at "moderate" temperatures from 190 to 200 degrees Celsius.

Metal 3D Printing Filament Spools, in this case by SteelFill and CopperFill colorFabb (Steel and Bronze), Ancient Bronze by Formfutura

Here are the key points about metal printing at home

Gets a unique metal surface and look
Ideal for jewelry, figurines, household utensils, replicas
Durability
Objects are not flexible (structural dependent)
Objects do not dissolve
Not considered food safe
Typical print temperature: 195 - 220°C
Table heating not required
Printing complexity is high, requires fine tuning of nozzle temperature, feed rate, post-processing

Preparing Your Home Printer for Metal 3D Printing

Since getting metal 3D prints is more difficult than usual, you may need to upgrade your 3D printer nozzle, especially if you are an entry-level printer. The metal filament wears it out quickly. There are hard-wearing hot-ends (like the E3D V6) that are themselves made of metal. They can withstand high temperatures and fit most printers. Be prepared for the fact that the nozzles will have to be changed frequently, because the metal filament is very abrasive. nine0014

You will also need to take care of the final finishing of the surface (cleaning, sanding, oiling, waxing or priming) so that the printed metal object shines as it should.

How much is metal filament for 3D printing?

And what about metal filament for 3D printing? - you ask. Here are some examples:

A 500-gram BFSteel and BFBronse coil from Bestfilament costs 1600–1800 ₽
ColorFabb's 750 gram Bronzefill spool is $56.36
ColorFabb's 750 gram Copperfill spool is $56.36
Protopasta's Polishable Stainless Steel PLA Composite is $56 for 56 grams
Protopasta's Rustable Magnetic Iron PLA Composite is $34. 99 for 500 grams

Industrial Metal 3D Printing

But what if you want better results or even all-metal 3D printing? Should a real "metal" 3D printer be purchased for business needs? We wouldn't recommend it - unless you're going to be doing it every day. A professional metal 3D printer is expensive: EOS or Stratasys devices will cost you 100-500 thousand dollars. In addition, the costs will be even greater, since you will have to hire an operator, a worker to maintain the machine, as well as to finalize the printouts (polishing, for example). Just a note: In 2016, an affordable metal 3D printer didn't exist. nine0014

Reducing Metal 3D Printing Costs

If you are not going to open a metal 3D printing business, but still need a professionally 3D printed metal part, it is better to contact the appropriate company that provides such services. 3D printing services like Shapeways, Sculpteo and iMaterialise offer direct metal printing. They currently work with the following metal materials in 3D printing:

aluminum
steel
brass
copper
bronze
sterling silver
gold
platinum
titanium

If you are a jeweler, you can also order wax models for casting in precious metals. If we talk about wax models, then in most cases it is they (with subsequent melting) that are used when printing with metals (including gold and silver). Not all orders are carried out directly by these firms. They usually turn to other metal 3D printing companies to complete the order. However, the number of such services around the world is growing rapidly. In addition, metal 3D printing techniques are becoming more and more common in companies that offer such services. nine0014

The reason 3D printing is so popular with large companies is that it can be used to build fully automated lines that produce "topologically optimized" parts. This means that it is possible to fine-tune the raw materials and make the components thicker only if they must withstand heavy loads. In general, the mass of parts is significantly reduced, while their structural integrity is preserved. And this is not the only advantage of this technology. In some cases, the product turns out to be significantly cheaper and affordable for almost everyone. nine0014

Please note that metal 3D printing requires special CAD software for modeling. It is worth paying attention to the recommendations of Shapeways - 3D printing metal guidelines. To delve further into the topic, check out Statasys’ information on related 3D printers and the nuances of metal 3D printing.

Here are some examples of Benchy test model prices for metal 3D printing:

Metal plastic: $22.44 (former alumide, PLA with aluminum)
Stainless steel: $83.75 (plated, polished)
Bronze: $299.91 (solid, polished)
Silver: $713.47 (solid, mirror polished)
Gold: $87.75 (gold plated, polished)
Gold: $12,540 (solid, 18K gold)
Platinum: $27,314 (solid, polished)

As you might expect, solid metal 3D printing prices are quite high.

Metal 3D printing. Applications

GE LEAP aircraft engine parts 3D printed at Avio Aero (Photo: GE)

There are several industries already using 3D printers to make everyday objects – you may not even know that these objects are printed. nine0014

The most common case is surgical and dental implants, which in this design are now considered the best option for patients. Reason: they can be tailored to individual needs.
Another industry is jewelry. Here, most manufacturers have abandoned resin 3D printing and wax casting, switching directly to metal 3D printing.
In addition, the aerospace industry is becoming more and more dependent on 3D printed metal objects. The Italian company Ge-AvioAero was the first to do all-metal 3D printing. It manufactures components for LEAP aircraft engines. nine0234
Another industry targeting metal 3D printing is the automotive industry. BMW, Audi, FCA are seriously considering this technology, not only for prototyping (3D printing has been used for this for quite some time), but also for making real parts.

Before metal 3D printing really takes off, however, there are some hurdles to overcome. And first of all, this is a high price, which cannot be made lower than during molding. Another problem is the low production speed. nine0014

3D metal printing.

Technologies

Most metal 3D printing processes start with an “atomized” powder

You can talk a lot about “metal” 3D printers, but their main problems remain the same as any other 3D – printers: software and hardware limitations, material optimization and multimateriality. We won't talk too much about the software, we'll just say that most of the major specialized software companies, such as Autodesk, SolidWorks and solidThinking, try to emphasize as much as possible the fact that as a result of the 3D metal printing process, you can get any shape you want. nine0014

In general, printed metal parts can be as strong as parts made by traditional processes. Parts made using DMLS technology have mechanical properties equivalent to casting. In addition, the porosity of objects made on a good "metal" 3D printer can reach 99.5%. In fact, manufacturer Stratasys claims that 3D printed metal parts perform above industry standards when tested for density. nine0014

3D printed metal can have different resolutions. At the highest resolution, layer thickness is 0.0008 - 0.0012" and X/Y resolution is 0.012 - 0.016". The minimum hole diameter is 0.035 - 0.045″. Let's, however, consider what metal 3D printing technologies are.

Metal 3D printing process #1:

Powder Bed Fusion

The metal 3D printing process that most of the relevant large companies use today is called Powder Bed Fusion. This name indicates that some source of energy (a laser or other energy beam) melts an "atomized" powder (i.e., a metal powder that is carefully ground into spherical particles), resulting in layers of a printed object. nine0014

There are eight major manufacturers of metal 3D printers in the world that already use this technology; while we are talking here, there are more and more such companies. Most of them are in Germany. Their technologies are called SLM (Selective Laser Melting - selective laser fusion) or DMLS (Direct Metal Laser Sintering - direct metal laser sintering).

Metal 3D printing process #2:

Binder Jetting

ExOne 3DP prints metal objects by binding the powder before firing it in a forge (photo: ExOne)

Another professional approach that also uses a powder base is called Binder Jetting. In this case, the layers are formed by gluing metal particles together and then sintering (or fusing) them in a high-temperature furnace, just like it is done with ceramics.

Another option, which is also similar to working with ceramics, is mixing metal powder into metal paste. A pneumatically extruded 3D printer (similar to a syringe bioprinter or an inexpensive food printer) forms 3D objects. When the required shape is reached, the object is sent to the furnace, i.e. in the mountains This approach is used in the Mini Metal Maker, apparently the only inexpensive "metal" 3D printer.

Metal 3D Printing Process #3:

Metal Deposition

It may seem that the only 3D printing process that is left out of working with metals is layer-by-layer deposition. This is not entirely true. Of course, on some desktop device, simply fusing metal threads onto the base will not work. However, very large steel companies can do it. And they do. There are two options for working with "metal surfacing".

One is called DED (Directed Energy Deposition) or Laser Cladding. Here, a laser beam is used to melt the metal powder, which is slowly released and solidifies as a layer, and the powder is fed using a robotic arm. nine0014

Usually the whole process takes place in a closed chamber, but in the MX3D project, conventional 3D printing techniques were used to build a full-size bridge. Another option for metal fusion is called EBAM (Electron Beam Additive Manufacturing - additive electron beam technology), which is essentially soldering, in which a very powerful electron beam is used to melt 3 mm titanium wire, and the molten metal forms very large finished structures. As for this technology, its details are known so far only to the military. nine0014

Metal 3D printing. Metals

3D Printing Metal #1: Titanium

Pure titanium (Ti64 or TiAl4V) is one of the most commonly used metals for 3D printing and is definitely one of the most versatile, strong and lightweight. Titanium is used both in the melting process in a preformed layer and in the process of spraying a binder and is used mainly in the medical industry (for the manufacture of personal prostheses), as well as in the aerospace industry, automotive and machine tools (for the manufacture of parts and prototypes). But there is one problem. Titanium is very reactive and explodes easily in powder form. Therefore, it is necessary that titanium 3D printing takes place in a vacuum or in an argon environment. nine0014

3D Printing Metal #2: Stainless Steel

Stainless steel is one of the cheapest 3D printing metals. At the same time, it is very durable and can be used in a wide range of manufacturing and even artistic and design applications. The type of steel alloy used also contains cobalt and nickel, is very difficult to break, and has a very high elasticity. Stainless steel is used almost exclusively in industry.

3D Printing Metal #3: Inconel

Inconel is a superalloy manufactured by Special Metals Corporation, its registered trademark. The alloy consists mainly of nickel and chromium and is very heat resistant. Therefore, it is used in the oil, chemical and aerospace (for black boxes) industries.

3D Printing Metal #4: Aluminum

Due to its lightness and versatility, aluminum is very popular in 3D printing. Aluminum alloys are commonly used. nine0014

3D Printing Metal #5: Cobalt-Chromium

This alloy has a very high specific strength (i.e. strength divided by density, which generally indicates the force required per unit area to break). It is most commonly used in the manufacture of turbines, dental and orthopedic implants, where 3D printing has become the dominant technology.

Metal for 3D printing №5. Copper and Bronze

With few exceptions, copper and bronze are used in wax melting processes, rarely in layer melting. The fact is that these metals are not very suitable for industry, they are more often used in the manufacture of works of art and crafts. ColorFabb offers both metals as the basis for a special metal filament. nine0014

Metal for 3D printing №6. Iron

Iron, incl. magnetic, also mainly used as an additive to PLA-based filaments, which are produced, for example, by ProtoPasta and TreeD.

Metal for 3D printing №7. Gold, Silver and Other Precious Metals

Most preformed layer companies can 3D print precious metals such as gold, silver and platinum. Here, along with the preservation of the aesthetic properties of materials, it is important to achieve optimization of work with expensive starting powder. Precious metal 3D printing is required for jewelry, medical applications and electronics. nine0014

Metal 3D printing. Printers

Do not even hesitate - the purchase of a metal 3D printer will not pass without a trace on your budget. It will cost at least 100-250 thousand dollars. Here is a list of a variety of "metal" printers, some of which can be found in firms providing 3D printing services.

Metal 3D Printer #1:

Sciaky EBAM 300 Metal Filament Printing

If you need to print really large metal structures, Sciaky's EBAM technology is your best bet. By order, the device can be built in almost any size. This technique is used mainly in the aerospace industry and the military. The largest of Sciaky's serial printers is the EBAM 300. It prints objects in a volume of 5791 × 1219 × 1219 mm.

The company claims the EBAM 300 is also one of the fastest industrial 3D printers on the market. A three-meter-sized titanium part for an aircraft is printed on it in 48 hours, while the material consumption is about 7 kg per hour. In general, forged parts that usually take 6-12 months to complete can be made in 2 days with this 3D printer. nine0014

Sciaky's unique technology uses a high energy electron beam that melts a 3mm titanium rod at a typical melting rate of 3 to 9 kg per hour.

Metal 3D Printer #2:

Fabrisonic UAM - Ultrasonic 3D Printing

Another way to print large metal parts is UAM (Ultrasound Additive Manufacturing Technology) from Fabrisonic. The devices of this company are three-axis CNC cutters, to which welding heads are added for the additivity of the process. The metal layers are first cut and then ultrasonically welded. The largest Fabrisonic 7200 printer operates in a volume of 2 x 2 x 1. 5 m.

Metal 3D Printer #3:

Concept Laser XLine 1000 - Metal Powder 3D Printing

The largest metal powder 3D printer on the market is the Concept Laser XLine with a volume of 1000. modeling - 630 × 400 × 500 mm, and itself the size of a house.

Its German company, one of the main suppliers of 3D printers for aerospace giants like Airbus, recently introduced a new machine, the Xline 2000.

This equipment uses two lasers and the working volume is 800 × 400 × 500 mm. Uses LaserCUSING laser technology (a variant of selective laser fusion) from Concept Laser, which allows you to print alloys of steel, aluminum, nickel, titanium, precious metals and even some pure substances (titanium and stainless steel).

Metal 3D printing. Services

There are more than 100 companies worldwide offering metal 3D printing services. We list the most popular services for consumer needs. nine0014

#1 Metal 3D Printing Service: Shapeways

The world's most popular 3D printing service, Shapeways offers two types of services. As a consumer, you can choose from a wide range of professionally designed objects, customize them, and then have them printed to your specifications. Like other 3D printing services, Shapeways offers a platform for designers to sell and print their work. Shapeways is also a good place for rapid prototyping: customers benefit from industrial-grade printers (EOS, 3D Systems) and personal technical support. nine0014

3D printing metals: aluminium, brass, bronze, gold, platinum, precious metal plating, silver, steel. There are also wax molds for jewelry purposes.

Metal 3D Printing Service #2: Sculpteo

Like Shapeways and i.materialise, Sculpteo is an online 3D printing service that allows anyone to upload 3D models and send them for fabrication in a wide range of materials. Like its competitors, Sculpteo provides a platform for hobbyists and professionals to showcase and sell their designs. The stable of Sculpteo printers includes highly professional machines from 3D Systems, EOS, Stratasys and ZCorp. Extensive technical documentation will help identify design flaws and select the right material for the project. nine0014

3D printing metals: alumide (plastic with aluminum particles), brass, silver.

Metal 3D Printing Service #3: iMaterialise

Materialise is a company that works with industrial clients to prototype 3D printed products. For casual users and designers, Materialize offers an online 3D printing service called i.materialise. As with Shapeways, this service allows anyone to upload their 3D designs and print them out. Once an object has been uploaded and successfully printed, a designer can list it for sale either in the gallery of the i.materalise online store or by embedding some code into their website. nine0014

3D printing metals: alumide (plastic with aluminum powder), brass, bronze, copper, gold, silver, steel, titanium.

Metal 3D Printing Service #4: 3D Hubs

Through 3D Hubs, you can search for individuals and businesses that offer 3D printing services in your area, upload STL files (which are immediately assessed for defects), and contact directly with service providers to get the job done.