Metal deposition 3d printer

Types of 3D Printing in Metal

Metal powder is the backbone of metal 3D printing. Though it’s difficult and dangerous to handle in its raw state, its unique features make it the preferred metal stock type. The vast majority of metal 3D printing technologies utilize metal powder. As a result, the major differences between types of metal printers relate to how they fuse the powder into metal parts. These methods vary greatly, ranging from using high energy lasers to fuse loose powder to extruding bound metal powder filament. In this article, we’ll take a look at the most heavily used types of metal 3D printing, how they work, and why they’re beneficial.

Powder Bed Fusion

Known by many names, powder bed melting is currently the most common type of metal 3D printing. These machines distribute a fine layer of powder over a build plate and selectively melt a cross section of the part into the powder layer. There are two distinct types of powder bed melting techniques: Selective Laser Melting and Electron Beam Melting.

Selective Laser Melting (SLM)

Also known as: Direct Metal Laser Sintering (DMLS), Selective Laser Sintering (SLS), Direct Metal Printing (DMP), Laser Powder Bed Fusion (LPBF).

The majority of Powder Bed Fusion machines are Selective Laser Melting (SLM) machines. SLM machines use high powered lasers to fuse metal layers into parts. After a print, an operator removes the part (or parts) from the powder bed, cuts the part away from the build plate, and post processes the part. It’s the current standard for metal printing -- most companies in Metal AM today sell SLM machines.

An SLM machine while printing.

As the most mature variety of metal 3D printing, SLM is often considered the standard that other technologies are evaluated against. SLM printed parts are great for precise, geometrically complex parts that would not be otherwise machinable. They fit into a wide variety of applications: from dental/healthcare to aerospace. Build volumes range from very small (100mm cube) to large (800mm x 500mm x 400mm) and print speed is moderate. Precision of these machines is determined by laser beam width and layer height. Most materials available to be 3D printed today can be used on an SLM machine.

While these machines are groundbreaking, a wide variety of facility and post processing requirements limit these machines to industrial users. SLM machines require trained professionals to operate them. Because of its intricate process, many parts need to be printed and tweaked a few times to yield results. After printing, most parts require significant post processing and heat treatment. In addition, the metal powder that these machines use is both extremely dangerous and expensive to handle: most fully baked SLM machines cost upwards of 1M dollars to implement and a dedicated technician to run.

Electron Beam Melting (EBM)

EBM machines use an electron beam instead of a laser to fabricate parts. GE Additive is the only company producing EBM machines. The electron beam yields a less precise part than SLM, but the process as a whole is faster for larger parts. These machines have almost all of the same constraints, costs, and issues as SLM machines, but are used more heavily in aerospace and medical applications than anywhere else. Similarly to SLM, EBM machines cost upwards of 1M to set up and require a dedicated technician to run.

Direct Energy Deposition

Direct energy deposition uses metal feedstock and a laser to fabricate parts. Unlike powder bed fusion, the stock (which can be powder or wire) and the laser both sit on a single print head that dispenses and fuses material simultaneously. The resultant parts are very similar to Powder Bed Fusion, with a few key differences and opportunities.

Powder DED

Also known as: Laser Material Deposition (LMD), Blown Powder

The sibling of Selective Laser Melting, Direct Energy deposition also uses a laser and metal powder to fabricate metal parts. Instead of spreading powder on a bed and melting it with a laser, DED machines precisely blow powder out of a print head onto a part, using an on-head laser to fuse it to the part in construction.

A BeAM DED 3D printer depositing and melting metal powder with a dual purpose print head.

As both machines use metal powder and a laser, parts printed with DED are very similar to those printed by SLM with one key exception: DED machines can utilize their unique powder distribution system to “heal” non printed parts that have deficiencies. Their available materials, post processing and powder management requirements are analogous to SLM, and machines also cost in the 1M dollar range.

Wire DED

Also known as: Electron Beam Additive Manufacturing, or EBAM

Wire DED machines use a laser to melt feedstock in a very similar manner to their powder DED relatives -- however, their feedstock is metal wire instead of blown powder. It’s a niche technology used with larger build volumes (as large as 5m x 1m x 1m) and faster print times at the expense of precision and quality. As a result, Wire DED parts are designed to be significantly larger and less precise than powder bed machines. These machines cost several million dollars per unit and are extremely uncommon in the space.

Binder Jetting

Binder Jetting is a large scale, high fidelity method of metal 3D printing that may replace SLM as the premier loose powder based method of 3D printing. The field has exploded from a single manufacturer to a variety of companies (including AM industry leaders) in the last two years. Due to its speed and scalability, it may be the technology that propels metal additive manufacturing capabilities into production volumes.

The technology behind metal binder jetting reflects what a conventional (2D) printer uses to quickly jet ink onto paper. First, a binder jetting machine evenly distributes metal powder over its print bed, forming an unbound layer. Then, a jetting head much like one in a 2D printer distributes binding polymer in the shape of the part cross section, loosely adhering the powder. The process repeats until the machine yields a finished build of completed parts.

A Digital Metal binder jetting machine, capable of producing fine detail.

Parts printed on Binder Jetting machines require a post processing step called “sintering” to become fully metallic. In this process, the printed part is heated in an oven to just below its melting temperature. The binding material burns away and the metal powder unites into a full metal part. This process can be done in batches, meaning that it doesn’t significantly affect throughput.

Vacuum furnaces are usually massive, industrial grade machines.

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Binder Jetting holds two main advantages over Selective Laser Melting. First, machines CAN print much faster by using multiple heads to jet in several places simultaneously. Second, the machine can make tens or even hundreds of the same part in one build. These parts can be sintered in a large furnace to achieve a manageable batch production infrastructure. As a result Binder Jetting is significantly faster on a per part basis than any other type of metal printing. With this speed (and powder management requirements) comes massive costs -- currently, the only machines in this space cost well over a million dollars.

Bound Powder Extrusion

Also known as: Atomic Diffusion Additive Manufacturing, Bound Powder Deposition

Bound Powder Extrusion (BPE) is an exciting newcomer to the metal additive manufacturing space. Unlike almost every other major 3D printing process, BPE machines do not use loose metal powder. Instead, the powder is bound together in waxy polymers in the same way that metal injection molding stock is created. The result is a material that’s much safer and easier to use than loose powder: bound powder extrusion material can be handled by hand and does not require the safety measures that loose powder machines do. BPE filament is extruded out of a nozzle in a manner very similar to standard FFF 3D printing, yielding a “green” part that contains metal powder evenly distributed in waxy polymer. After printing, BPE has two post processing steps: first, the polymer is mostly dissolved in a “wash” machine; second the washed part is sintered in an oven (similar to binder jetting). During the sintering process, the part shrinks to account for the space opened up by the dissolved binder, yielding a fully metallic part.

The Metal X printing system contains a metal 3D printer, part washing station, and sintering furnace.

As a filament based printing process, the part constraints of BPE parts closely mirror those of conventional FFF plastic printing: it works well for almost all part geometries, and can print with open cell infill. Parts printed on BPE systems still often require post-processing -- heat treatment for parts that need advanced properties (though this is required for every metal), and post machining/polishing for enhanced surface finishes -- but there’s no powder management and reduced facility requirements. BPE machines leverage a simpler process to be much more affordable than all other major types of metal 3D printing, with machines costing between $120,000 and $200,000. The Markforged Metal X uses this process -- to learn more about this process, check out this article on the Metal X process.

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Best metal 3D printers in 2022: comprehensive overview

What is the best metal 3D printer in 2022?

Over the past few years, there has been a surge in both supply and demand for metal 3D printers.

Manufacturers are launching metal additive manufacturing machines that are faster, easier to use, and more powerful with an increasing number of compatible metals.

Many businesses are adopting these 3D metal printing technologies to produce cost-effective metal parts and prototypes, benefiting as well from increased freedom of design linked to additive manufacturing. They are suitable for a variety of industries such as aerospace, automotive, health, engineering, and more.

Although metal 3D printer prices have been slowly and slightly decreasing, these machines are still relatively expensive acquisitions, mostly ranging from $80K to almost $1M.

With our metal 3D printer selection, we aim to provide a comprehensive overview of what’s available from well-established and distributed brands, at various price points, and with different metal 3D printing technologies.

The best metal 3D printers in 2022

Brand	Product	Build size	Country	Price Approximate starting prices based on supplier-provided information and public data. Prices may vary by region, over time and do not include additional products or services (taxes, shipping, accessories, training, installation, …).
Markforged	Metal X (Gen 2)	300 × 220 × 180 mm11.81 × 8.66 × 7.09 in	United States	$ 99,500125 000 €88,260 £14,831,072 ¥	Quote
Xact Metal	XM200C	127 × 127 × 127 mm5 × 5 × 5 in	United States	$ 110,000100 000 €97,574 £16,396,160 ¥	Quote
Pollen AM	Pam Series MC	⌀ 300 x 300 mm	–	$ 140,000135 000 €124,186 £20,867,840 ¥	Quote
TRUMPF	TruPrint 1000	100 × 100 × 100 mm3.94 × 3.94 × 3.94 in	–	$ 170,000170 000 €150,797 £25,339,520 ¥	Quote
3D Systems This brand is a certified partner from our network.	DMP Flex 100	100 × 100 × 80 mm3.94 × 3.94 × 3.15 in	–	$ 245,000245 000 €217,325 £36,518,720 ¥	Quote
EOS	EOS M 100	100 × 100 × 95 mm3.94 × 3.94 × 3.74 in	Germany	$ 350,000350 000 €310,464 £52,169,600 ¥	Quote
XJet	Carmel 700M	501 × 140 × 200 mm19.72 × 5.51 × 7.87 in	–	$ 599,000599 000 €531,337 £89,284,544 ¥	Quote
Desktop Metal	Production System P-1	200 × 100 × 40 mm7.87 × 3.94 × 1.57 in	United States	upon request	Quote
Desktop Metal	Studio 2	300 × 200 × 200 mm11.81 × 7.87 × 7.87 in	United States	upon request	Quote
Digital Metal	DM P2500	203 × 180 × 69 mm7.99 × 7.09 × 2.72 in	–	upon request	Quote
Formalloy	L-Series	1000 × 1000 × 1000 mm39. 37 × 39.37 × 39.37 in	United States	upon request	Quote
GE Additive	Arcam EBM Spectra L	⌀ 350 x 430 mm	United States	upon request	Quote
GE Additive	M2 Series 5	250 × 250 × 350 mm9.84 × 9.84 × 13.78 in	–	upon request	Quote
Renishaw	RenAM 500E	245 × 245 × 335 mm9.65 × 9.65 × 13.19 in	–	upon request	Quote
SLM Solutions	SLM 125	125 × 125 × 75 mm4.92 × 4.92 × 2.95 in	Germany	upon request	Quote
SPEE3D	LIGHTSPEE3D	300 × 300 × 300 mm11.81 × 11.81 × 11.81 in	–	upon request	Quote
TRIDITIVE	AMCELL	⌀ 300 x 350 mm	Spain	upon request	Quote
Velo3D	Sapphire	⌀ 315 x 1000 mm	–	upon request	Quote

Expand to see more specs

Technology: The technologies listed above are main categories of metal 3D printing technologies. Most manufacturers have their own branded technologies, which fall into the main categories that are listed in the table.

The products in the table are ranked by price (low to high).

Brand	Product	Technology	Build size	Country	Price Approximate starting prices based on supplier-provided information and public data. Prices may vary by region, over time and do not include additional products or services (taxes, shipping, accessories, training, installation, …).
Markforged	Metal X (Gen 2)	Extrusion	300 × 220 × 180 mm11.81 × 8.66 × 7.09 in	United States	$ 99,500125 000 €88,260 £14,831,072 ¥	Get a quote
Xact Metal	XM200C	SLM/DMLS	127 × 127 × 127 mm5 × 5 × 5 in	United States	$ 110,000100 000 €97,574 £16,396,160 ¥	Get a quote
Pollen AM	Pam Series MC	Extrusion	⌀ 300 x 300 mm	–	$ 140,000135 000 €124,186 £20,867,840 ¥	Get a quote
TRUMPF	TruPrint 1000	SLM/DMLS	100 × 100 × 100 mm3. 94 × 3.94 × 3.94 in	–	$ 170,000170 000 €150,797 £25,339,520 ¥	Get a quote
3D Systems This brand is a certified partner from our network.	DMP Flex 100	SLM/DMLS	100 × 100 × 80 mm3.94 × 3.94 × 3.15 in	–	$ 245,000245 000 €217,325 £36,518,720 ¥	Get a quote
EOS	EOS M 100	SLM/DMLS	100 × 100 × 95 mm3.94 × 3.94 × 3.74 in	Germany	$ 350,000350 000 €310,464 £52,169,600 ¥	Get a quote
XJet	Carmel 700M	Material Jetting	501 × 140 × 200 mm19.72 × 5.51 × 7.87 in	–	$ 599,000599 000 €531,337 £89,284,544 ¥	Get a quote
Desktop Metal	Production System P-1	Binder Jetting	200 × 100 × 40 mm7.87 × 3.94 × 1.57 in	United States	upon request	Get a quote
Desktop Metal	Studio 2	Extrusion	300 × 200 × 200 mm11. 81 × 7.87 × 7.87 in	United States	upon request	Get a quote
Digital Metal	DM P2500	Material Jetting	203 × 180 × 69 mm7.99 × 7.09 × 2.72 in	–	upon request	Get a quote
Formalloy	L-Series	Directed Energy Deposition	1000 × 1000 × 1000 mm39.37 × 39.37 × 39.37 in	United States	upon request	Get a quote
GE Additive	Arcam EBM Spectra L	EBM	⌀ 350 x 430 mm	United States	upon request	Get a quote
GE Additive	M2 Series 5	SLM/DMLS	250 × 250 × 350 mm9.84 × 9.84 × 13.78 in	–	upon request	Get a quote
Renishaw	RenAM 500E	SLM/DMLS	245 × 245 × 335 mm9.65 × 9.65 × 13.19 in	–	upon request	Get a quote
SLM Solutions	SLM 125	SLM/DMLS	125 × 125 × 75 mm4. 92 × 4.92 × 2.95 in	Germany	upon request	Get a quote
SPEE3D	LIGHTSPEE3D	Material Jetting	300 × 300 × 300 mm11.81 × 11.81 × 11.81 in	–	upon request	Get a quote
TRIDITIVE	AMCELL	Extrusion	⌀ 300 x 350 mm	Spain	upon request	Get a quote
Velo3D	Sapphire	SLM/DMLS	⌀ 315 x 1000 mm	–	upon request	Get a quote

Main types of metal 3D printing technologies

The four main types of 3D metal printing technologies are:

• Metal Powder Bed Fusion 3D printing (SLS, SLM, DMP)
• Directed Energy Deposition (DED)
• Metal filament extrusion (FFF, FDM)
• Material Jetting and Binder Jetting

There are also some resin-based metal 3D printers, and metal sheet lamination 3D printers, but they are harder to come by.

It is not uncommon to see different acronyms and names for similar technologies. Each brand markets their own, proprietary methods. Some metal 3D printer companies even use a mix of different technologies.

A breakdown of the metal 3D printer market by technology types. Source: Aniwaa database (2019)

Here we provide a deeper look into each 3D metal printer from our list. They are grouped together according to their main 3D printing technology type (powder bed fusion, material/binder jetting, extrusion, and DED).

Extrusion-based metal 3D printer selection (FFF, FDM)

Extrusion consists of heating the material (filament) and pushing it through a nozzle. In the metal 3D printing case, the filament is generally made up of metal particles mixed into a binding agent.

After the part is 3D printed, the result is a raw object or part; it must go through several post-processing steps– such as debinding and sintering– to attain its final form.

Most extrusion-based metal 3D printing processes include these steps. The above illustration is sourced from Desktop Metal (Bound Metal Deposition™ process).

Desktop Metal’s Studio is an office-friendly, end-to-end metal 3D printing system. Aside from the printer, the Studio line also includes a debinding machine and a furnace for sintering. Indeed, parts 3D printed with this Desktop Metal 3D printer are “green”.

The Studio printer, with its proprietary Bound Metal Deposition technology, uses filament that is filled with small, metal rods. During debinding, the binding material (wax and polymer binders) is dissolved thanks to a proprietary liquid substance. The part is left porous, and must go in the furnace for its particles to fuse and densify the part.

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MarkForged is specialized in continuous fiber 3D printing, but also offers metal 3D printing with their Metal X system, featuring Atomic Diffusion Additive Manufacturing (ADAM) technology.

This MarkForged 3D printer extrudes metal-filled plastic filament to form the part, which must then be washed with a special debinding fluid (Wash-1 Station) and then sintered in a furnace (Sinter-1 or Sinter-2 MarkForged machines).

Available metal 3D printer filament includes various Steels (h23, A2, D2 tool steels, 316L stainless steel) as well as Inconel, Copper, and Titanium.

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Canada-based Rapidia offers an interesting and unique way to 3D print metal. They use a water-based metal paste, which eliminates the need for chemical debinding. The water evaporates during the 3D printing process, so the part only needs to go through the furnace in order to completely solidify and attain its final form.

Confirmed, available paste types include several Stainless Steels, Inconel, and a few ceramics. Copper, Tungsten Chrome Carbide, Titanium, and various other metals are in development.

The ExOne Metal Designlab, designed in collaboration with Rapidia, works on the same basis.

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Pollen AM is a French manufacturer that has been producing pellet 3D printers since 2013. Their Pam Series MC is a delta-style 3D printer (cylindrical build volume) that can print metals, ceramics, and thermoplastics.

It extrudes injection-molding-grade pellets instead of metal 3D printer filament, driving material costs down significantly. Pollen AM names their technology “Pellet Additive Manufacturing”.

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This machine was built with one goal: enable mass production 3D printing of metal parts 24/7. The AMCELL is fully automated, with auto feedstock control, environment control (temperatures, humidity, air filtering), and an ejection system fitted with a conveyor belt.

Rather than providing one, big build volume, the TRIDITIVE AMCELL boasts eight delta-style ø 220 x 330 mm build areas. Its eight “robots” deposit metal-infused filament to create 3D metal parts. TRIDITIVE states that resulting parts are similar to ones produced with traditional MIM (Metal Injection Molding) methods.

TRIDITIVE’s technology is called Automated Multimaterial Deposition®.

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Metal powder bed fusion 3D printer selection (SLS, SLM, DMP, and more)

At the moment, the most commonly used metal additive manufacturing technology is powder bed fusion 3D printing. Simply put, the 3D printer creates objects out of a bed of powdered metal by using a powerful laser.

3D Systems, a historical actor on many 3D printing fronts, presents the DMP FLEX 100 as a fast, precise, and affordable metal 3D printer. It offers impressive part repeatability and surface finishes, of around 20 μm and 5 Ra μm respectively. DMP stands for Direct Metal Printing.

The printer comes with 3D Systems’ software 3DXpert All-in-One Software Solution for Metal Additive manufacturing. Their LaserForm metal 3D powders are certified.

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This compact metal 3D printer is destined for the production of small parts in small quantities. Its material portfolio is especially interesting for medical use cases, namely dental crowns and bridges. EOS certified metal powders include Cobalt-Chrome, Stainless Steel, and Titanium.

The EOS M100’s laser spot is precise enough to provide a great level of detail, backed by 200 W of powder.

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Originally a Swedish company, Arcam was acquired by GE Additive a few years ago. The Arcam EBM Spectra L is up to 20% faster than its predecessors and is able to reduce part costs by around 10%.

This metal 3D printer is dedicated to Titanium 3D printing, but Copper is in the pipeline as well. Its laser beam power is equal to 4.5 kW, partly explaining the printer’s high melting capacity and productivity. Common applications for this printer include orthopedic implants and parts for the aerospace industry.

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Concept Laser is the company behind GE Additive’s M2 Series 5. It offers an easy, optimized workflow, with a separate processing chamber and handling area that is integrated into the system. This closed-loop material system ensures a safe environment that is free of powder for the operator.

The M2 metal additive manufacturing solution is compatible with a range of metals, from Stainless Steels to Aluminum, Nickel, Titanium, and Cobalt-Chrome.

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The RenAM 500E is Renishaw’s entry-level metal additive manufacturing solution. It offers a relatively large build volume and powder can be handled via a dedicated glove box to avoid powder from getting free.

This system is also equipped with an oxygen sensor and a proprietary emission-filtering system branded SafeChange™.

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Officially established in 2006, SLM Solutions has been a historical player in the powder bed fusion industry for many years. The SLM 125 boasts an open software architecture that allows users to tweak the system’s parameters according to specific use cases, materials, and general needs.

Options such as laser monitoring and melt pool monitoring are available for businesses that require full transparency and control over their production series.

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The TruPrint 1000 is TRUMPF’s most compact metal 3D printing system, with a 100mm-tall cylindrical build volume. It is suitable for the production of small parts and prototypes, and even small production series when equipped with the multilaser option that increases the printer’s speed.

This metal 3D printer can be operated remotely via a tablet application, which also gives access to its onboard camera stream.

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The Velo3D Sapphire is a high-volume metal 3D printer from the US designed for production series. This metal 3D printer features Velo3D’s Intelligent Fusion technology to allow for complex geometries and 0° overhangs.

The system is also equipped with a range of metrology sensors that measure each and every layer that is 3D printed.

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The XM200C is Xact Metal’s entry-level metal 3D printing solution. It is suitable for both research purposes and small production series. The XM200C benefits from a proprietary Xact Core gantry system for precise movements with a fusing speed of up to 500 mm/s.

Xact Metal offers their own materials, branded Xact Powder, including various Stainless Steels, Super Alloys, Tooling Steels, Aluminum, Titanium, Bronze, and Copper. Advanced users are able to use their own metal powders if needed.

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Metal material jetting and binder jetting 3D printers

Material jetting 3D printers are equipped with various inkjet printheads (somewhat similar to 2D printing) that jet material onto a surface. The material then hardens, and another layer of “metal ink” is jetted on top.

Binder jetting is a similar process, but it is a binding agent that is jetted atop a layer of powder.

The Production System by Desktop Metal was designed for mass production. It is advertised by Desktop Metal as being a fast, cost-effective metal additive manufacturing solution, with a cost per part up to 20 times lower than with other metal 3D printing systems.

This Desktop Metal 3D printer is equipped with over 16,000 nozzles that are mounted onto a “print bar” that recoats the build plate with powder at the same time, hence explaining the technology’s name: Single Pass Jetting™.

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Digital Metal, a Höganäs Group company, creates incredibly detailed metal parts with their DM P2500 system. It is able to print 3D metal parts with an accuracy as high as 0.001mm (1µ), and with a medical-grade surface quality of around 0.006mm (6µ).

Another interesting feat to point out is that almost 100% of leftover powder can be recycled for future prints. This metal AM machine is able to churn out serial production series efficiently and reliably; one of the company’s first DM P2500 printers has been running 24/7 since 2013, according to Digital Metal.

The Digital Metal DM P2500 is a certified metal 3D printer (CE and UL) that is compatible with certified metal materials (ISO 22068).

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Australian manufacturer SPEE3D has developed an impressively fast metal 3D printing technology called Supersonic Deposition. The technology is based on metal cold spray, using compressed air to “jet” metal powder through a nozzle at high speeds.

This enables the LightSPEE3D to 3D print at up to 100 grams per minute and with a range of metals including copper.

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XJet developed an impressive, proprietary jetting technology they call NanoParticle Jetting™. This inkjet method disperses millions of tiny droplets that contain nanoparticles of solid metal. The liquid material comes in cartridges that are easy to insert into the printer.

After being printed, the metal parts must go through support removal and sintering processes to attain their final form.

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DED: Directed Energy Deposition metal additive manufacturing systems

Directed Energy Deposition (DED) is comparable to filament extrusion. The metal material is pushed through a special nozzle, like with FFF/FDM, but a powerful laser beam solidifies the material at its deposition point.

Formalloy produces a range of metal DED 3D printers with up to 5 axes of motion. They can be used to produce metal parts but also to repair or clad existing parts.

Different laser wavelengths are available, as well as different build volumes: 200 x 200 x 200 mm, 500 x 500 x 500 mm, and 1000 x 1000 x 1000 mm. Metal 3D printers from Formalloy can be customized depending on company requirements.

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Alternative metal 3D printers and special mentions

Hybrid metal manufacturing systems

Some manufacturers are specialized in hybrid metal manufacturing systems. They combine both subtractive and additive manufacturing methods, often with robotic arms that are able to move on more than three axes.

Some of the biggest actors on the hybrid metal AM system market are:

• Gefertec (Germany)
• DMG Mori (Germany)
• Matsuura (Japan)
• Sodick (United States)

XXL-sized metal 3D printers for industrial production

For those that require very large metal parts, there are several huge, industrial machines that offer gigantic build volumes for industrial production. To name a few:

• Sciaky EBAM 300
• Titomic TKF1000
• ADC Aeroswift
• ADIRA AddCreator
• Fabrisonic SonicLayer 4000
• ExOne X1 160PRO
• InssTek MX-600
• BeAM Modulo 400
• Optomec Lens CS 600
• Additive Industries MetalFAB1

Metal 3D printers from China

There has recently been a lot of growth in the metal 3D printer market in Asia, and more specifically in China. Some Chinese brands have been upping their game in that respect, providing industrial-grade metal 3D printing options:

• Farsoon
• ZRapid Tech
• Shining 3D
• Wiiboox

However, we feel that they are not yet playing in the same league as the 3D printers from our main selection, mostly due to a lack of distribution networks, after-sales service and training, and other factors which tend to matter when considering them together as a whole.

R&D metal 3D printers for labs

In certain cases, metal 3D printers are used for research purposes to develop and test new materials. There are a few machines that are specifically designed for this:

• Open Additive PANDA-6”
• Freemelt ONE
• Sharebot metalONE

Pros and cons of metal 3D additive manufacturing

Benefits of 3D printing metal parts

• On-demand production: Metal additive manufacturing offers more flexibility and control over the production line.

• Complex designs made possible: With 3D printing technology, it is possible to create highly detailed and intricate parts that would have to be broken down into several pieces with traditional methods.

• Waste reduction: Compared to CNC milling, for example, metal AM produces much less waste as it only consumes the material needed for a certain part. This is more true for extrusion-based methods than it is for powder-based methods, where it isn’t always possible to re-use 100% of unsintered or unbinded material.

• Lighter parts: Whereas metal parts are usually completely solid infill-wise with other methods, 3D printing allows parts to be more or less hollow without undermining their strength and resistance.

• Cost-effectiveness: All the above benefits of metal 3D printing can inherently reduce costs per part, although high metal 3D printer prices do represent a significant entry barrier. Reaching a positive return on investment can take a while depending on your throughput.

Limits of metal 3D printing

• Metal 3D printing prices: Metal AM systems are still quite expensive, as are metal powders and metal filaments. There are hidden costs, too (e.g. energy consumption, learning curve, etc.).

• Environmental constraints and safety precautions: Most metal 3D printers have a large footprint and require specific operating environments with controlled temperatures, hygrometry, and more.

• Post-processing: In many cases it is necessary for parts to be post-processed, whether it’s debinding and sintering or finishing touches for surface quality.

• Physical properties: It can be difficult to achieve the same physical properties that traditionally manufactured metal parts have. There are a number of factors (e.g. anisotropy) to take into account during the design process and file preparation before even trying to 3D print a certain part.

Metal 3D printing materials

Which metals can you 3D print?

A growing number of metals and metal alloys can be 3D printed. These are the main ones:

• Aluminum
• Titanium
• Nickel, Inconel
• Copper
• Bronze
• Cobalt, Cobalt-Chrome
• Steels (tooling, maraging, stainless)
• Precious metals (gold, silver, platinum)

Which metal 3D printing material formats are available?

Metal 3D printing material can be found in various formats, catering to different metal 3D printing methods. The most common are:

• Powder
• Wire
• Filament

It is also possible to find metal 3D printing resin as well as metal sheets for lamination-based 3D printers.

Metal 3D printer price: how much does a metal 3D printer cost?

Industrial metal 3D printer prices generally range from about $30,000 to over one million dollars for the most premium, industrial-grade metal additive manufacturing systems.

Additional costs to consider are the materials for metal 3D printing, which can cost a few hundred USD/kg, as well as costs linked to post-processing (tools, time, etc.).

Applications for metal AM systems

There are thousands of possibilities and use cases for metal 3D printing in a wide range of industries. A few industries have been incrementally using metal AM:

• Aerospace
• Automotive
• Medical

Whether it’s for tooling, replacement parts, or final products, many businesses can benefit from metal 3D printing.

However, metal additive manufacturing isn’t necessarily beneficial for every single metal part. Although some metal 3D printing systems have a relative capacity for serial production, it is generally cheaper to keep using traditional methods for simple parts.

For cases where complex geometries, rapid prototyping, and mass customization are required, metal AM is convenient and efficient.

Metal 3D printing services: order 3D metal parts online

For professionals with limited office space and human resources, low budgets, and/or few needs of custom parts and prototypes, metal 3D printing services can be an ideal solution.

These additive manufacturing service companies own a variety of high-quality 3D printers with different technologies, and their professionals are experts in 3D printing. It is possible to order metal 3D parts on-demand, without acquiring a 3D printer or having to buy a certain material for one-time use.

Here are some of the most trusted 3D printing service providers that offer metal printing services:

• Sculpteo
• Shapeways
• Hubs (ex 3D Hubs)
• Stratasys
• i.materialise
• Protolabs

Metal 3D printing technologies and acronyms

Many manufacturers develop proprietary variations of existing technologies and label them their own registered names:

• Powder Bed Fusion (PBF): DMLS (Direct Metal Laser Sintering), DMP (Direct Metal Printing), LaserCUSING, LBM (Laser Beam Melting), LMF (Laser Metal Fusion), SLS (Selective Laser Sintering), SLM (Selective Laser Melting)
• Directed Energy Deposition (DED): DMT (Direct Metal Tooling), EBAM (Electron Beam Additive Manufacturing), EBM (Electron Beam Melting), LENS (Laser Engineered Net Shaping), LMD (Laser Metal Deposition)
• Metal Material Jetting (MJ) or Binder Jetting (BJ): Magnet-o-Jet, Nanoparticle Jetting, SPJ (Single Pass Jetting), Metal Jet
• Metal filament extrusion/Fused Filament Fabrication (FFF): ADAM (Atomic Diffusion Additive Manufacturing), CEM (Composite Extrusion Modeling), FDM (Fused Deposition Modeling), FFD (Fused Feedstock Deposition), FMP (Filament Metal Printing), BMD (Bound Metal Deposition), MIM (Metal Injection Molding)
• Lamination: SL (Sheet Lamination), UAM (Ultrasonic Additive Manufacturing)
• Metal resin 3D printing: DLP (Digital Light Processing), FluidFM, SLA (Stereolithography)

Metal 3D printing FAQ

Is 3D printed metal strong?

Metal 3D printed parts can be as strong (or even stronger) as metal parts created with traditional manufacturing processes such as casting. The part’s strength will, however, depend on the metal AM method used and the conditions in which it is 3D printed.

When was 3D metal printing invented?

Metal 3D printing became possible in the 1990s with the development of Selective Laser Melting technology. However, 3D metal printing only started to gain traction and public interest from around 2010 onwards.

How does metal 3D printing work?

There are several ways to 3D print metal. Layers of metal filament can be deposited one after the other, producing a green part that must later go through debinding and sintering steps. It is also possible to fuse metal powder particles together with a laser, or with an inkjet printhead that deposits drops of binding material onto the powder.

3D metal printing - technologies and printers / Habr

3D metal printing is becoming more and more popular. And this is not surprising: each metal print material offers a unique combination of practical and aesthetic properties in order to meet the requirements of various products, whether they are prototypes, miniatures, decorations, functional parts or even kitchen utensils.

The reasons for printing with metals are so strong that 3D printing with metals is already being introduced into mass production. In fact, some 3D printed parts have already caught up, and some have even surpassed those produced by traditional methods. nine0005

Traditional production from metals and plastics is very wasteful - in the aircraft industry, for example, up to 90% of materials go to waste. The output of products, in some industries, is no more than 30% of the material used.

Metal 3D printing uses less energy and reduces waste to a minimum. In addition, the finished 3D printed part can be up to 60% lighter than a milled or cast part. The aviation industry alone will save billions of dollars in fuel costs by reducing the weight of structures. But strength and lightness are needed in other industries. Yes, and economy too. nine0005

Metal 3D printing at home

What can you do if you want to try 3D metal printing at home? Metal printing requires extremely high temperatures, it is unlikely that you can use a regular FDM 3D printer for this, at least not yet. The situation may change in a few years, but now this is not available to home 3D equipment.

If you want to make metal-looking printouts at home, the best option is to use plastic containing metal particles. nine0005

Such as Colorfabb Bronzefill or Bestfilament Bronze.

These filaments contain a significant percentage of metal powders, but also enough plastic to print at low temperatures with any 3D printer. At the same time, they contain enough metal to look, feel and have a weight close to that of a metal object.

Items made of iron-containing filament even rust under certain conditions, which adds credibility, but they cannot rust through and deteriorate from this - and this is their advantage over real metal objects. nine0005

Benefits of these materials:

• Unique look of printouts
• Ideal for jewelry, figurines, homewares and decor
• High strength
• Very little shrinkage during cooling
• Heated table optional

Cons:

• Low product flexibility, depends on print design
• Not considered safe in contact with food
• Requires fine tuning of nozzle temperature and filament feed rate
• Product post-processing required - grinding, polishing
• Rapid wear of extruder nozzle - filament with metal is very abrasive compared to conventional materials

The general printing temperature range is typically 195°C - 220°C.

Industrial metal 3D printing

If you are looking to purchase a real metal 3D printer for enterprise use, then there are two pieces of news for you - good and bad. nine0005

The good news is that their range is quite wide and continues to expand - it will be possible to choose a device that meets any technical requirement. Further in the article you can see this.

The only bad news is the prices. The cost of professional metal printing printers starts anywhere from $200,000 and goes up indefinitely. In addition, even if you choose and purchase the most inexpensive of them, the purchase of consumables, scheduled maintenance with the replacement of components, and repairs will be a separate blow. We do not forget about the staff and the costs of post-processing products. And at the stage of preparation for printing, you will need special software and people who can handle it. nine0005

If you are ready for all these expenses and difficulties - read on, we will present some very interesting samples.

https://youtu.be/20R9nItDmPY

Metal 3D printing application

Some industrial sectors already use metal 3D printers, they have become an integral part of the production process, which the average consumer may not be aware of:

The most common example is medical implants and dental crowns, bridges, prostheses, which are already considered the most patients. Reason: They can be 3D printed faster and cheaper and tailored to the individual needs of each patient. nine0005

A second, equally common example: jewelry. Most major manufacturers are slowly moving away from 3D printing molds and stencils to direct metal 3D printing, and titanium printing is allowing jewelers to create designs that were previously impossible.

In addition, the aerospace industry is becoming more and more dependent on 3D printed metal products. Ge-AvioAero in Italy is the world's first fully 3D printed factory that produces components for LEAP jet engines. nine0005

The next industry using metal 3D printers is the automotive industry. BMW, Audi, FCA are already seriously considering applying the technology to series production, not just prototyping, where they have been using 3D printing for years.

It would seem - why reinvent the wheel? But here, too, 3D metal printing has found application. For several years now, manufacturers of bicycle components and frames have been using 3D printing. Not only in the world, but also in Russia, this has become widespread. Exclusive bike manufacturer Triton is finishing up a project with a 3D printed titanium frame element that reduces weight without compromising strength. nine0005

But before metal 3D printing really takes over the world, there are a few major challenges that need to be overcome. First of all, it is the high cost and low speed of production of large series by this method.

Metal 3D Printing Technology

Much can be said about the use of metal-printing 3D printers. There are specifics, but the main issues are the same as with any other 3D printers: software and hardware limitations, material optimization and multi-material printing. We won't talk much about software, except to mention that major publishers such as Autodesk, SolidWorks, and SolidThinking all develop software products for use in metal 3D printing so that users can bring any shape imaginable to life. nine0005

Recently, there have been examples that 3D printed metal parts can be as strong as traditionally produced metal components, and in some cases even surpass them. Created using DMLS, the products have the same mechanical properties as those of solid cast counterparts.

Let's look at the available metal 3D printing technologies:

Process #1: Layer by layer powder fusion

The process of 3D printing metals that most major companies use these days is known as powder bed fusion or sintering. This means that a laser or other high-energy beam fuses particles of evenly distributed metal powder into a single whole, creating layers of the product, one after another. nine0005

There are eight major metal 3D printer manufacturers in the world, most of them located in Germany. Their technologies go under the acronym SLM (Selective Laser Melting) or DMLS (Direct Laser Metal Sintering).

Process #2: Binder Jetting

Another professional method with layer-by-layer bonding is gluing metal particles for subsequent firing in a high-temperature furnace, where the particles are fused under pressure, making up a single metal whole. The printhead applies the coupling solution to the powder substrate in layers, like a conventional printer on sheets of paper, after which the product is sent to firing. nine0005

Another similar but different technology based on FDM printing is kneading metal powder into metal paste. Using pneumatic extrusion, the 3D printer extrudes it, much like a 3D construction printer does with cement, to form 3D objects. After the desired shape is printed, the objects are also sintered in an oven. This technology is used by the Mini Metal Maker, perhaps the only more or less affordable metal 3D printer ($1600). Add the cost of a small kiln. nine0005

Process #3: Welding

You might think that among the metal printing technologies there is no similar to the usual FDM, however, this is not entirely true. You can't melt metal filament in the hot end of your 3D printer, but the big manufacturers have the technology and use it. There are two main ways to print with solid metal material.

One of them is called DED (Directed Energy Deposition), or laser cladding. It uses a laser beam to fuse metal powder that is slowly released and deposited from an extruder, forming layers of an object with an industrial arm. nine0005

This is usually done inside a closed chamber, however, with MX3D, we see the possibility of implementing a similar technology in the construction of a real full-size bridge, which is due to be printed in 2017 in Amsterdam.

The other is called EBM (Electron Beam Manufacturing), a technology for forming layers of metal raw materials under the influence of a powerful electron beam, with its help create large and very large structures. If you do not work in the defense complex of the Russian Federation or the United States, then you are unlikely to see this technology alive. nine0005

A couple of new, barely emerging technologies, used so far only by their creators, are presented below - in the section on printers.

Metals used

Ti - Titanium

Pure titanium (Ti64 or TiAl4V) is one of the most commonly used metals for 3D printing, and certainly one of the most versatile as it is both strong and lightweight. It is used both in the medical industry (in personalized prosthetics) and in the aerospace and automotive industries (for the manufacture of parts and prototypes), and in other areas. The only catch is that it is highly reactive, which means it can explode easily when in powder form, and should definitely only be used for printing in an inert Argon gas environment. nine0005

SS - Stainless steel

Stainless steel is one of the most affordable metals for 3D printing. At the same time, it is very durable and can be used in a wide range of industrial and artistic applications. This type of steel alloy containing cobalt and nickel has high elasticity and tensile strength. 3D printing of stainless steel is used mainly only in heavy industry.

Inconel

Inconel is a modern superalloy. It is manufactured by Special Metals Corporation and is a patented trademark. Consists, for the most part, of nickel and chromium, has high heat resistance. It is used in the oil, chemical and aerospace industries (for example: to create distribution nozzles, on-board “black boxes”). nine0005

Al

Due to its inherent lightness and versatility, aluminum is a very popular metal for 3D printing applications. It is usually used in the form of various alloys, forming their basis. Aluminum powder is explosive and is used in printing in an inert Argon gas environment.

CoCr - Cobalt Chrome

This metal alloy has a very high specific strength. It is used both in dentistry - for 3D printing of dental crowns, bridges and clasp prostheses, and in other areas. nine0005

Cu - Copper

With rare exceptions, copper and its alloys - bronze, brass - are used for casting using burnt patterns, and not for direct metal printing. This is because their properties are far from ideal for industrial 3D printing applications, they are more commonly used in arts and crafts. With great success, they are added to plastic filament - for 3D printing on conventional 3D printers.

Fe - Iron

Iron and magnetic iron ore are also mainly used as an additive to PLA filament. In large-scale industry, pure iron is rarely used, and we wrote about steel above. nine0005

Au, Ag - Gold, silver and other precious metals

Most powder fusing 3D printers can work with precious metals such as gold, silver and platinum. The main task when working with them is to ensure the optimal consumption of expensive material. Precious metals are used in 3D printing of jewelry and medical products, as well as in the production of electronics.

Metal 3D printers

#1: Sciaky EBAM 300 - titanium rod

For printing really large metal structures, Sciaky's EBAM is the best choice. This device can be any size, to order. It is used primarily in the US aerospace and defense industries.

As a production model, Sciaky sells the EBAM 300. It has a working area with sides of 5791 x 1219 x 1219 mm.

The company claims the EBAM 300 is one of the fastest commercially available industrial 3D printers. Structural elements of aircraft, the production of which, according to traditional technologies, could take up to six months, are now printed within 48 hours. nine0005

Sciaky's unique technology uses a high power electron beam gun to melt 3mm thick titanium filament, with a standard deposition rate of about 3-9 kg/hr.

#2: Fabrisonic UAM - ultrasonic

Another way to 3D print large metal parts is Ultrasound Additive Manufacturing Technology (UAM) from Fabrisonic. The brainchild of Fabrisonic is a three-axis CNC machine with an additional welding head. The metal layers are first cut and then welded together using ultrasound. Fabrisonic's largest 3D printer, "7200", has a build volume of 2 x 2 x 1.5 m.

# 3: Laser XLine 1000 - metal powder

One of the largest metal powder 3D printers on the market has long been the Concept Laser XLine 1000. It has a build area of ​​630 x 400 x 500mm and takes up space like a small house.

The German company that made it, which is one of the suppliers of 3D printers for aerospace giants such as Airbus, recently introduced a new printer, the XLine 2000.

2000 has two lasers and an even larger build volume of 800 x 400 x 500 mm. This machine, which uses patented LaserCUSING technology (a type of selective laser melting), can create objects from alloys of steel, aluminum, nickel, titanium, precious metals, and some pure materials (titanium and bar steels.)

All major players in the metal 3D printing market: EOS, SLM, Renishaw, Realizer and 3D Systems, as well as Shining 3D, a rapidly growing company from China. nine0005

# 4: M Line Factory - Modular 3D Factory

Displacement: 398.78 x 398.78 x 424.18 mm
1 to 4 lasers, 400 - 1000 watts each.

The M Line Factory concept is based on the principles of automation and interaction.

M Line Factory, from the same Concept Laser and operating on the same technology, does not focus on the size of the workspace, but on the convenience of production - it is a modular architecture apparatus that divides production into separate processes in such a way that these processes can occur simultaneously, not sequentially. nine0005

This new architecture consists of 2 independent machine nodes:

M Line Factory PRD (Production Unit)

Production Unit consists of 3 types of modules: dosing module, printing module and overflow module (tray for finished products). All of them can be individually activated and do not form one continuous piece of equipment. These modules are transported through a system of tunnels inside the machine. For example, when new powder is supplied, the empty powder storage module can be automatically replaced with a new one without interrupting the printing process. Finished parts can be moved outside the machine and immediately automatically replaced by the next jobs. nine0005

M Line Factory PCG (Processing Unit)

This is an independent data processing unit that has an integrated sieving and powder preparation station. Unpacking, preparation for the next print job and sieving take place in a closed system, without the participation of the operator.

# 5: ORLAS CREATOR - 3D printer ready to go

The creators of ORLAS CREATOR position this 3D printer as the most affordable, easy-to-use and ready-to-use, does not require the installation of any additional components and third-party programs, capable of printing directly from a complete CAD / CAM file of their own design. nine0005

All the necessary components are installed in a relatively compact case, which needs a space of 90x90x200 cm. It does not take up much space, although it looks impressive, and it weighs 350 kg.

As can be understood from the table given by the manufacturer, the metal powder is sintered by a rotating laser system, in layers 20-100 µm thick and with a “pixel” size of only 40 µm, in a nitrogen or argon atmosphere. You can connect it to a regular household power supply if your wiring can withstand a load of 10 amperes. Which, however, does not exceed the requirements of an average washing machine. nine0005

Laser power - 250 watts. The working area is a cylinder 100 mm in diameter and 110 mm in height.

#6: FormUp 350 - Powder Machine Part Method (PMPM)

The FormUp 350, powered by Powder Machine Part Method (PMPM), was created by AddUp, a joint venture between Fives and Michelin. This is the latest metal 3D printing machine, first introduced in November at Formnext2016.

The principle of operation of this 3D printer is the same as that of the above colleagues, but its main feature is different - it lies in its inclusion in PMPM. nine0005

The printer is designed specifically for industrial use, in 24/7 mode, and is designed for exactly this pace of work. The PMPM system includes quality control of all components and materials, at all stages of their production and distribution, which should guarantee consistently high performance, in which Michelin has a huge long-term experience.

# 7: XJET - NanoParticle Jetting - metal inkjet

The nanoparticle injection technology involves the use of special sealed cartridges with a solution containing a suspension of metal nanoparticles. nine0003 Nanoparticles are deposited and form the material of the printed product.

Considering the claimed features of the technology (the use of nanosized metal particles), it is easy to believe the creators of the device when they claim its unprecedented accuracy and print resolution.

# 8: VADER Mk1 - MagnetoJet - Metal Inkjet

Zack Vader's MagnetoJet technology is based on the study of magnetohydrodynamics, and more specifically, the ability to control molten metal using magnetic fields. The essence of the development is that a drop of a strictly controlled size is formed from molten aluminum, and printing is carried out with these drops. nine0005

The size of such a droplet is from 200 to 500 microns, printing occurs at a speed of 1000 drops per second. Printer working area: 300 mm x 300 mm x 300 mm

Media: Aluminum and its alloys (4043, 6061, 7075). And, even though it is only aluminum for now, the printer is 2 times faster than powder ones and up to 10 times cheaper.

The Mk2 is scheduled for release in 2018 and will be equipped with 10 printheads, which should increase print speed by 30 times.

# 9: METAL X - ADAM - atomic diffusion

Markforged introduced a new metal 3D printing technology - ADAM, and a 3D printer working on this technology - Metal X.

ADAM (Atomic Diffusion Additive Manufacturing) - atomic diffusion technology. Printing is done with metal powder, where the metal particles are coated with a synthetic binder, which is removed after printing, allowing the metal to fuse together.

The main advantage of the technology is the absence of the need to use ultra-high temperatures directly in the printing process, which means that there are no restrictions on the refractoriness of the materials used for printing. Theoretically, the printer can create 3D models from heavy-duty tool steels - now it is already printing with stainless steel, and titanium, Inconel and D2 and A2 steels are in development. nine0005

The technology allows you to create parts with a complex internal structure, such as in a honeycomb or in porous bone tissue, which is difficult with other 3D printing technologies, even for DMLS.

Product size: up to 250mm x 220mm x 200mm. The layer height is 50 microns.

Look, soon it will be possible to print a high-quality knife - from scratch, in a couple of hours, giving it any most intricate design.

Want more exciting news from the world of 3D technology? nine0005

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Metal 3D printing using pure steel and alloys makes it possible to obtain strong functional parts of mechanical and industrial products.

Any metal 3D printing technology allows you to 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? nine0005

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.

3D PRINT STEEL

Strength of steel printed parts.

The cast steel part (left) compared to the printed version (center) shows the tolerances possible with the technology. Hinge, right, printed as a whole, no assembly required (Source: Desktop Metal)

The most common question when it comes to a 3D printed metal model is "Will it be as strong as a forged or cast part?". The short answer is yes... and no. nine0005

3D printed steel parts can be just as strong, and sometimes more durable, 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 needs of 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. nine0005

Queen Maxima of the Netherlands officially opens a 3D printed metal bridge. Photo by Adriaande Groot (Source: MX3D)

A steel part printed on a 3D printer using one of the technologies, in particular laser powder sintering (LPBF), 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. nine0005

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 manufactured 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. nine0005

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 details, 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. nine0005

MX3D Wire Arc Additive Manufacturing (WAAM) printed steel architectural support (Source: MX3D)

3D printing with steel is also a more sustainable and cost-effective practice 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, leaving a lot of waste in the process. With additive manufacturing, you only use the material you need to make the finished product. nine0005

Steel 3D printing is not intended to replace traditional methods in all areas, but it can 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. nine0005

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.

STEEL FOR 3D PRINTING

Types of steel for 3D printing

Metal powder is the most used metal material for 3D printing (Source: GKN Additive)

There are thousands of different grades of steels and alloys with different mechanical properties used in traditional production, but in 3D printing there are only a few dozen, and some of them are unique, created specifically for this technology. Steel options include:

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

nine0026

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, designed to solve the problems that occur when using classical production methods. nine0005

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 with the hardness of low alloy steel. like 4140. The company claims that customers can go to market with parts made of this material and skip the galvanizing step to protect products from corrosion. nine0005

ExOne offers two special blends of steel and bronze that the company says allows 3D printed steel parts to have enhanced 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 switch to the technology. Some metal powder manufacturers, such as GKN, also make custom powders for specific 3D printing applications. nine0005

HOW TO PRINT 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 a few of the most common application examples. nine0005

Fused Deposition Printing (FDM)

BCN3D's Epsilon printer extrudes stainless steel metal filament (Source: BCN3D)

Fused Deposition Forming (FDM) is a new technology for metal 3D printing, but it is developing rapidly as more printer manufacturers certify metal filaments for use on their printers, e.g. Ultimaker, BCN3D, Makerbot, Raise3D. This method is still much more popular for printing plastics, but with new plastic filaments filled with stainless steel powder, strong metal parts can be produced. nine0005

Materials for FDM printing were 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. nine0005

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

Forward AM's Ultrafuse 316L stainless steel filament produces finished parts with material properties that the company claims are comparable to injection molded metal parts. nine0005

(Source: BCN3D)

While 3D printing with metallic materials may not be suitable for applications with tough strength requirements (such as aerospace), the economics of producing simple metal components without critical loads on an affordable FDM printer may outweigh the inability to use them in some applications. .

Ideal use cases for this technology are metal prototype parts and finished parts that will not be subjected to extreme stress. nine0005

Bound Metal Deposition (BMD)

Desktop Metal's Studio System 3D printer used metal rods connected together and extruded layer by layer to form a metal part (Source: Desktop Metal)

Similar to FDM, metal mesh deposition method (BMD) or bonded powder extrusion (BPE) is an extrusion-based 3D printing process. 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. nine0005

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. nine0005

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

For example, Shukla Medical uses Markforged's Metal X printer to print steel prototypes of its orthopedic implant removal instruments. nine0005

Laser powder sintering

Laser powder sintering technology uses one or more lasers to melt powdered metal layer by layer into a desired shape (Source: GE Additive)

Powder material laser sintering (LPBF), also known as selective laser sintering (SLM), is the most common type of metal 3D printing and accounts for 80% of all metal 3D printers on the market. nine0005

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

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

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 manufacturing methods. nine0005

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

nine0292 Binder 3D printing technology uses metal powder and a binder to form metal parts (Sorrce: ExOne)

Ink jet bonding is another powder printing method in which layers of metal powders are bonded using a liquid binder rather than a laser. During post-processing, the binder is removed.

The application of the binder stands out for its high printing speed compared to other 3D printing methods or traditional manufacturing, and the metal parts made with this technology have material properties equivalent to parts 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. nine0005

Ideal applications for bonded metal blasting are 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. nine0005

Electron Beam Melting (EBM)

(Source: GE Additive)

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

The recoater moves the powder onto the printing plate, and the 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. nine0005

EBM can be much faster than SLM, but SLM produces smoother, 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. nine0005

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

Cold Spray

(Source: Impact Innovations)

Cold spray 3D printing technology is carried out by injecting metal powders through the nozzle of a jet device 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. nine0005

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. It does not require post-processing and usually leaves a small carbon footprint due to the combination of efficient additive manufacturing and the ability to be used in the right place. For these reasons, this technology is used in the military and aerospace industries worldwide. nine0005

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 high-strength steel substrates in automobiles can be susceptible to thermal repair methods such as welding.

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

WAAM steel parts from MX3D (Source: MX3D)

Direct energy deposition (DED) uses welding powder or wire that enters through a nozzle and is fed into a 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 manufacturing large objects as a whole, as well as for complex geometries that require extensive machining - DED can get such parts much closer to a finished state than traditional CNC machining. nine0005

Since DED uses a coating process, it can be used to create complex geometries in 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. nine0005

Micro 3D printing

Micro parts printed from steel (Source: 3D MicroPrint)

Micro-scale additive manufacturing, or micro 3D printing, makes it possible to manufacture products with a resolution of a few microns (or less). There are three micro 3D printing methods to produce metal parts.

LMM (lithography-based metal fabrication) is a light-based technology that allows the creation of tiny parts from raw materials, including stainless steel, for applications such as surgical instruments and micro-mechanical parts. nine0005

Electrochemical deposition is the latest micrometal 3D printing process developed by the Swiss company Exaddon.

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