Metal 3d printing materials

The Best Metal 3D Printing Materials for Additive Manufacturing

Nearly all metal 3D printing processes rely on metal powder. Whether used as a raw material or bound in a filament, it is the essential ingredient that enables machines to additively fabricate parts. This means the availability of metal 3D printing materials in additive manufacturing depends almost entirely on how easily the powderized form can be fused together. Aluminum powder, for example, is more difficult to meld together than steels that are much more easily bonded, and is therefore a lot less common of a metal 3D printed material.

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The most useful metal 3D printing materials offer manufacturers the greatest value-add compared to traditional manufacturing methods. Oftentimes this stems from machinability. Hard-to-machine materials like tool steels and titanium are traditionally very tough to work with, but because machinability does not equate to printability, these metals can be made on a 3D printer with minimal labor at a fixed, low cost per part.

Let’s review some of the metal 3D printing materials available on the Markforged Metal X system, and the pros and cons that each material brings to the manufacturing process.

3D printed 17-4 PH Stainless Steel grippers

Stainless Steel

Stainless steel is characterized by high strength and excellent corrosion resistance. This material is used across a vast range of industries and applications from manufacturing to assistive technology. Examples of 3D printed stainless steels include the extremely corrosion resistant 316L and the heat treatable 17-4 PH Stainless Steel.

Tool Steels

As the name suggests, this class of steels is used for a variety of manufacturing tooling. Anything on a production line that cuts, stamps, molds, or forms is probably made out of tool steel. Tool steels can withstand such harsh conditions because of their high hardness, and excellent high heat and abrasion resistance. Because of these properties, tool steels are very difficult and expensive to machine, making them an ideal candidates to be 3D printed. Popular powders and filaments include A2, D2, and h23 Tool Steel.

Titanium

This metal is strong, incredibly lightweight, and heat and chemical resistant. Normally, titanium is extremely challenging to machine (contributing to its high cost), making it a great metal 3D printing material. The most common 3D printed titanium is Titanium 64 (Ti-6Al-4V) and is used in situations when a very high strength to weight ratio is beneficial, such as aircraft.

3D printed Inconel 625 crucible clips

Inconel 625

While 3D printers can be used to produce parts out of common metals such as steel, they can also fabricate parts out of superalloys that are uniquely suited for extreme environments. Inconel 625 is a strong, stiff, and very corrosion- and heat-resistant nickel-based superalloy that is often used in places like turbines and rockets. Other types of Inconel, namely Inconel 718, don’t have the same heat resistance that Inconel 625 has. The material is traditionally wildly expensive to machine; conversely, Inconel can be purchased in powder form and 3D printed for a fraction of the cost, opening the door to affordable Inconel components.

Copper

Because it conducts heat and electricity far better than traditional metals, copper has long been used in industrial fabrication. As a 3D printing material, copper is used for heat sinks and heat exchangers, power distribution components such as bus bars, manufacturing equipment including spot welding shanks, antennae for RF communications, and more.

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The current list of metal 3D printing materials is relatively short and focused on higher grade materials that are most financially beneficial to fabricate. However, as metal 3D printing matures, expect to see more and cheaper metal 3D printing filaments and powders available across different metal printing platforms. These materials, feeding off of the same cost benefits as the metals mentioned in this post, will open up new applications for metal printing and further its adoption by the manufacturing masses.

4 Best Materials for Metal 3D Printing

“Metal 3D printing” is an umbrella term that is used to describe several manufacturing processes for additive manufacturing of metal parts. The material is processed in a layer-by-layer manner, through sintering, welding, or melting. Two common metal 3D printing processes are Selective Laser Melting (SLM) and Direct Metal Laser Sintering (DMLS). Both of these use powder-bed fusion technology. While metal 3D printing can produce parts from a large range of metals and metal alloys, the best materials for metal 3D printing are stainless steel, tool steels, titanium, and Inconel® (nickel-based) alloys.

This article will define what metal 3D printing is, how it works, discuss the four best materials for metal 3D printing, and what materials work best in different applications.

1. Stainless Steel

Stainless steel is widely known for its ability to withstand corrosion, high strength, and excellent aesthetic appearance. Parts printed with stainless steel can have the same or even greater strength than parts created using traditional manufacturing methods. The strength, hardness, and other properties of 3D-printed stainless steel depend mainly on the specific technology used to print the part.

Stainless steel-printed parts have found application in many industries, including aerospace, automotive, military hardware, and medical. Compared to other metal 3D printing materials, stainless steel parts can be made with the smoothest surfaces because of the addition of chromium.

Stainless steel powder used for 3D printing comes in a variety of grades and alloys, including 316L, 304L, 630, 410, 420, 254, 17-4 PH, 15-5PH, Ph2, and GP1. Of these, 316L is the most commonly used grade in metal 3D printing. It has a composition of 66-70% iron enhanced with 16-18% chromium, 11-14% nickel, 2-3% molybdenum, and less than 0. 03% carbon. This 3D printing material is known for its ductility and good corrosion resistance.

2. Tool Steels

Tool steels are a family of iron-based alloys containing relatively high levels of carbon, which form carbides with other alloying elements, including tungsten, chromium, vanadium, and molybdenum. Tool steels offer an excellent combination of high-temperature strength, hardness, and wear resistance. These steels are commonly applied in the production of molds, stamps, and cutting tools in multiple industries. The tools are used to manufacture geometries that are used in other product manufacturing processes, including extrusion, cutting, casting, injection molding, stamping, and component assembly. The following tool steel options are available for metal 3D printing—D2, M2, h23, h21, MS1, and 1.2709.

3. Titanium

Titanium is the most-used metal in the additive manufacturing industry. It is widely employed in the medical, aerospace, automotive, and electronic industries, among others. Titanium and its alloys have high mechanical strength. They also offer better corrosion resistance than stainless steel.

The following titanium material options are available for metal 3D printing—Ti-6Al-4V, Beta 21S, Cp-Ti (commercially pure titanium), and TA15.

4. Inconel® 625

Inconel® 625 is a nickel-based superalloy that offers high strength and can retain its strength over a wide temperature range. Due to its excellent corrosion and oxidation resistance, it is considered ideal for corrosive environments. Inconel®625 finds application in the marine, energy, and chemical processing industries. Some applications of Inconel® 625 include boat propellers and heat exchanger casings.

What Is 3D Printing?

3D printing is a fabrication method where layers or materials are built up to create a three-dimensional object. The object is built up layer-by-layer, adding and joining the material from each new layer to the previous layer until the complete shape of the part has been created. Software applications that work to direct the 3D printing process are the computer programs that specify how to create the part in layers from a digital CAD file or model. This method of manufacturing is ideal for both simple and complex designs. Essentially, it is capable of creating virtually any 3D object imaginable.

For more information, see our guide on 3D Printing.

What Is Metal 3D Printing?

Metal 3D printing is a method of creating metal parts or products that adapts the general principles and methods of additive manufacturing methods and applies them to powdered metals. 3D printing always involves building a part using powder or filament wire, layer-by-layer, under computer control.

There are a number of ways to join together the successive layers of metal powder to form the final shape. They can be melted by a laser or electron beam, sprayed with a binding agent (binder jetting), or directly printed as molten droplets heated from metal filaments using Direct Energy Deposition (DED) or Fused Deposition Modeling (FDM) printers.

Figure 1 below is an example of a metal 3D printer (DMLS):

What Metals Can You 3D Print?

Metal 3D printing can be performed using a wide range of metal powders. These include, but are not limited to, steel, aluminum, stainless steel, copper, cobalt, tungsten, titanium, and nickel-based alloys. Precious metals like platinum, gold, palladium, and silver can also be used in 3D printing.

How Does Metal 3D Printing Work?

The working principles of a metal 3D printing method depend on the material used, whether that be a powder, filament, or wire. Out of these three options, printing with powder is the most common method.

With powdered metal 3D printing, the metal powder for the first layer is spread out by the powder coater, or recoater, on the floor of the build platform. A high-powered laser or electron beam is then used to selectively bind together the material as it scans the powder. This creates one solid layer of the object. The platform is then displaced downwards by 50-200 microns while another even layer of metallic powder is distributed over the previous layer and the process is repeated.

Metal wires, on the other hand, are the most affordable raw material form for metal 3D printing. The wire is melted with a plasma arc, laser, or electron beam. Direct Energy Deposition (DED) is an example of a 3D printing method that uses metal wires to produce parts. It is primarily used for repairs or for adding features to existing metal parts.

Metal filaments are just thin plastic wires impregnated with metal particles. This raw material choice makes sense when using Fused Deposition Modeling (FDM) printers. FDM works by extruding the heated filament through a nozzle onto the build platform to create a part. After printing, the part is placed on a debinding station to melt the plastic away using a solvent and then sent to a sintering furnace to fuse the metal particles together into a solid metal piece.

How To Select the Best Materials for Metal 3D Printing

To select the best metal 3D printing materials for your project, follow the steps below:

Define the performance requirements of the part to be produced. The requirements can include both environmental conditions to which the part will be exposed as well as mechanical stresses that are expected in the operating state.
Compare the performance requirements to the material specifications. This means checking the properties of the material to assure that that will satisfy the end-use requirements and operating conditions. For example, do you need a material with good mechanical strength or good corrosion resistance?
Choose the material that best fits the performance and part requirements expected so that it will provide reliable operation and good service life.

What Are the Best Metal 3D Printers?

Listed below are some of the best metal 3D printers that can be used to print parts for a wide range of end-use applications:

MarkForged Metal X: This 3D printer uses atomic diffusion additive manufacturing—a proprietary 3D printing technology—to print metal prototypes. A range of metals can be printed with this machine, and it is very cost-effective compared to other metal 3D printers.
Digital Metal DM P2500: The Digital Metal DM P2500 form is classified as a material jetting 3D printer. This equipment has an incredibly high print resolution and allows the metal powder to be reused—leading to less waste. It also allows for the printing of complex parts and maximal use of the print volume to produce a large number of small parts by printing the objects on top of each other.
Xact Metal’s XM200C: The Xact Metal XM200C is an affordable powder-bed fusion 3D printing technology. This machine was specifically developed to be a cost-effective and high-performance metal 3D printer. It uses proprietary technology to 3D print metal at very high speeds compared to other printers.

Is 3D Printed Metal Durable?

Yes, 3D-printed metals can be durable when the right material, process, settings, and procedures are chosen. The strength and durability of metal printed parts are dependent on several variables, including the type of metal used, the selection of the 3D printing method, the shape of the part, the post-processing steps taken, and end-use application.

Summary

The article reviewed the four (4) best materials to use for the metal 3D printing of parts and products. To learn more about metal 3D printing materials and whether it’s applicable to your project, contact a Xometry representative.

Xometry provides a wide range of manufacturing capabilities, including 3D printing and other value-added services for all of your prototyping and production needs. Visit our website to learn more or to request a free, no-obligation quote.

Copyright and Trademark Notices

Inconel® is a registered trademark of Huntington Alloys division of Special Metals Corp., Huntington, WV.

Disclaimer

The content appearing on this webpage is for informational purposes only. Xometry makes no representation or warranty of any kind, be it expressed or implied, as to the accuracy, completeness, or validity of the information. Any performance parameters, geometric tolerances, specific design features, quality and types of materials, or processes should not be inferred to represent what will be delivered by third-party suppliers or manufacturers through Xometry’s network. Buyers seeking quotes for parts are responsible for defining the specific requirements for those parts. Please refer to our terms and conditions for more information.

Team Xometry

This article was written by various Xometry contributors. Xometry is a leading resource on manufacturing with CNC machining, sheet metal fabrication, 3D printing, injection molding, urethane casting, and more.

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?

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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

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• Or on our website: http://3dtool.ru

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Metal 3D Printing - The Essential Guide

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. nine0002

Metal 3D printing has grown in popularity over the past few years. 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. In fact, some of the printed parts are just as good (if not better) than those made with traditional methods. nine0014

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. nine0014

So, what do we need to know about metal 3D printing?

3D metal printing at home

If you want to make objects at home that will look like metal, it is best to pay attention to 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 metal powders added to it. ColorFabb, ProtoPasta and TreeD Filaments all 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.

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

Here are the key points about metal printing at home

Gets a unique metal surface and look
Ideal for jewelry, figurines, housewares, replicas
Durability
Objects are not flexible (structure dependent)
Objects do not dissolve
Not considered food safe
Typical print temperature: 195 - 220°C
Extremely low shrinkage on cooling
No table heating 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 does metal filament for 3D printing cost?

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

ColorFabb's 750 gram Bronzefill spool is $56.36
ColorFabb 750g Copperfill Coil $56.36
Protopasta's Polishable Stainless Steel PLA Composite is $56 for 56 grams of
Protopasta's Rustable Magnetic Iron PLA Composite is $34.99 for 500 grams of

Industrial metal 3D printing

But what if you want a better result or even full 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

Lowering 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 they (with subsequent melting) 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 aluminium)
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. nine0249
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

Metal 3D 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". formed layer)

The metal 3D printing process used by most relevant large companies 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.

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). nine0014

Metal 3D printing No. 2:

binder Jetting (spraying the binder)

under 3DP-technology EXONE Metal objects are printed by binding the powder in the mountain : 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. nine0014

Another option, which is 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: 9Metal 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". nine0014

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.

Normally the whole process takes place in a closed chamber, but the MX3D project used conventional 3D printing techniques 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. nine0014

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 Chrome

gap). It is most commonly used in the manufacture of turbines, dental and orthopedic implants, where 3D printing has become the dominant technology.

3D printing metal #5. Copper and bronze

With some 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.

3D printing metal #6. Iron

Iron, incl. magnetic, also mainly used as an additive to PLA-based filaments, which are produced, for example, by ProtoPasta and TreeD. nine0014

3D printing metal #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.

Sciaky's largest production printer is the EBAM 300. It prints objects in a volume of 5791 x 1219 x 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

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. The metal powder 3D printer is the Concept Laser XLine 1000. It has a modeling volume of 630 x 400 x 500 mm and is the size of a house. nine0014

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 machine uses two lasers and has a working volume of 800 x 400 x 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). nine0014

Metallic 3D printing. Services

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

#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 to 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

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

Metal 3D Printing Service #3: iMaterialise

Materialise is a company that works with industrial customers to prototyping 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 site. 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 companies that offer 3D printing services in your area, upload STL files (which are immediately evaluated for defects ) and contact service providers directly to get the job done.