Metal 3d printing canada

FAQ's

How much does your 3D printing service cost?

The cost of your 3D printed parts depends on factors such as part volume, part complexity, choice of material, which 3D printing technology is used, and if any post processing is required. For more details on these cost factors, see our article on the cost of 3d printing. To check the cost of your 3D printed part, simply upload a CAD (. STL) file and select your material and 3D printing technology to receive a quote within seconds.

How do you guarantee the quality of my prints?

Your parts are made by experienced 3D printing shops within our network. All facilities are regularly audited to ensure they consistently meet the Hubs quality standard. We include a standardized inspection report with every order and offer a First Article Inspection service on orders of 100+ units.

We have partners in our network with the following certifications, available on request: ISO9001, ISO13485 and AS9100.
Follow this link to read more about our quality assurance measures.

How do I select the right 3D printing process for my prints?

You can select the right 3D printing process by examining which materials suit your need and what your use case is.

By material: if you already know which material you would like to use, selecting a 3D printing process is relatively easy, as many materials are technology specific.
By use case: once you know whether you need a functional or visual part, choosing a process is easy.

For more help, read our guide to selecting the right 3D printing process. Find out more about Fused Deposition Modeling (FDM), Selective Laser Sintering (SLS), Multi Jet Fusion (MJF) and Stereolithography (SLA).

How can I reduce the cost of my 3D prints?

In order to reduce the cost of your 3D prints you need to understand the impact certain factors have on cost. The main cost influencing factors are the material type, individual part volume, printing technology and post-processing requirements.

Once these have been decided, an easy way to further cut costs is to reduce the amount of material used. This can be done by decreasing the size of your model, hollowing it out, and eliminating the need for support structures.

To learn more, read our full guide on how to reduce the cost of 3D printing.

Where can I learn more about 3D printing?

Our knowledge base is full of in-depth design guidelines, explanations on process and surface finishes, and information on how to create and use CAD files. Our 3D printing content has been written by an expert team of engineers and technicians over the years.

See our complete engineering guide to 3D printing for a full breakdown of the different 3D printing technologies and materials. If you want even more 3D printing, then check out our acclaimed 3D printing handbook here.

We have an extensive range of online resources developed to help engineers improve their capabilities.

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The impact of 3D printing and FrameCAD technologies on home construction in Canada

In 2014, a breakthrough began in the field of building construction. Buildings are built from concrete using a 3D printer. Many people already know what a 3D printer is - it is a numerically controlled machine that uses the layer-by-layer method of creating a part.

Vancouver's high home prices make buying a home an impossible dream for most residents. Therefore, fortunately for many who want to buy a house for themselves, an affordable alternative will appear on the market - houses built by 3D printers.

New construction solution based on laser 3D printing of custom modular and steel beams and panels. The technology allows you to quickly create completely new tasks for printing. These steel parts are created with the design of the building under construction in mind, and then sent to the construction site and assembled in a short time.

Construction company LifeTec Construction Group uses a 3D printer to print metal structures to speed up the building process. The company is based in Vancouver.

Traditionally, large wooden trusses are used in the construction of small residential buildings. Their production noticeably slows down the construction process.

The new technology involves the replacement of wooden trusses with metal ones. At the same time, there is an important feature - they are printed on a special 3D printer using Framecad technology. It was developed in New Zealand and has since been tested around the world. Builders say building is faster and more efficient when trusses can simply be printed.

In addition to speed, builders note the increased durability of such structures. Printing also allows for less construction labor, which is especially true in Vancouver.

It is impossible to distinguish a 3D printed house from a traditional house. A 3D printer is laying the foundation of a house by pouring cement in layers. Then roofing, electricity and plumbing are added. For a small fee, customers can customize the settings for their future homes and thus design their own home the way they want. A four-bedroom house will only cost $20,000. The foundation of the house with an area of ​​2500 sq.m. can be built in 24 hours.

Benefits of 3D printed houses

• Uses lightweight metal parts that are stronger and more durable than regular construction wood.
• Easy and quick to assemble.
• Low labor intensity, it will help to make up for the lack of construction labor.

Of course, 3D printing will be increasingly used in construction. Thus, the main US military department has already declared its interest in new technologies and has allocated a substantial amount for research. There are similar projects involving public and private investors in other countries. This is not surprising - humanity is growing at a rapid pace, and everyone needs housing, and 3D printing is proving to be a quick and cheap construction option. Therefore, in 5-10 years, the expression "print a house" is unlikely to surprise anyone.

Steel 3D printing - a quick guide

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

Let's see how a 3D printed steel part 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.

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

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

Parts printed from steel are used in the aerospace industry, for the military, 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.

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

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

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

The main advantage of printing with steel is not only its strength, but also the unique ability to create internal channels and lattice fillings in parts, which is impossible using 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.

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

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

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

Types of steel for 3D printing

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:

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

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

• Low alloy steel (4140).

• Structural alloyed (20MnCr5).

Recently, unique alloys have been developed specifically for 3D printing to solve the problems that come with traditional manufacturing methods.

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

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

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

How to print with steel

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

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

Fused Deposition Printing (FDM)

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

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

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

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

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

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

Bound Metal Deposition (BMD)

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.

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

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

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

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

Laser powder sintering.

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

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

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

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

Binder Jetting

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

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

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

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

Electron Beam Melting (EBM)

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

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

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

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

Cold Spray

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

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

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

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

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

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

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

Micro 3D printing

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

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