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Sintered aluminum 3d printer
Aluminum (AlSi10Mg) 3D Printing Service
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Proto Labs, Inc.
5540 Pioneer Creek Dr.
Maple Plain, MN 55359
United StatesP: 877.479.3680
F: 763.479.2679
E: [email protected]Best-in-Class Online Quoting
After uploading your part design, you'll receive an online quote that includes manufacturing analysis to help improve part manufacturability. Within your quote, you can also adjust quantity and material and see price changes in real-time.
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3D-printed aluminum offers high temperature and corrosion resistance and an excellent strength-to-weight ratio
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Aluminum (AlSi10Mg) is comparable to a 3000 series alloy that is used in casting and die casting processes. It has good strength-to-weight ratio, high temperature and corrosion resistance, and good fatigue, creep and rupture strength. AlSi10Mg also exhibits thermal and electrical conductivity properties. Final parts built in AlSi10Mg receive stress relief application.
Primary Benefits
- High stiffness and strength relative to weight
- Thermal and electrical conductivity
- High temperature and corrosion resistance
Aluminum (AlSi10Mg) Material Properties
- US
- Metric
*All of the figures contained on this data sheet are approximate and dependent on a number of factors, including but not limited to, machine and process parameters. The information provided is therefore not binding and not deemed to be certified
3D-Printed Aluminum Part Dimensions
Maximum part size and minimum feature size will vary based on selected resolution. 3D-printed aluminum is available in high, normal, and large format resolutions.
| Resolution | US | Metric | |
| Maximum Dimensions | High (20 μm) | 3. 8 in. x 3.8 in. x 3.7 in. | 98mm x 98mm x 94mm |
| Normal (30 μm) | 9.6 in. x 9.6 in. x 13.0 in. | 244mm x 244mm x 330mm | |
| Large Format (40 μm) | 31.5 in. x 15.7 in. x 19.7 in. | 800mm x 398mm x 500mm | |
| Minimum Feature Size | High (20 μm) | 0.015 in. | 0.381mm |
| Normal (30 μm) | 0.030 in. | 0.762mm | |
| Large Format (40 μm) | 0.0015 in. | 0.381mm |
Large Aluminum 3D-Printed Parts
In need of larger additive parts? Our large format 3D printer can support aluminum material and has a build volume of 31.5 in. x 15.7 in. x 19.7 in. (800mm x 400mm x 500mm).
Learn More
Applications for 3D-Printed Aluminum
Due to its high strength-to-weight ratio, 3D-printed aluminum is frequently used in the automotive and aerospace industries for parts such as:
- Gearboxes
- Housings
- Brackets
- Heat exchangers
- Engine parts
Related Resources
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Direct metal laser sintering (DMLS) produces complex, durable, lightweight metal parts.
Depending on the design, DMLS can be a reliable way to manufacture metal parts.
Read Design Tip
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Metal 3D Printing Service for Custom Parts
Back
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Materials
Materials by Service
Injection MoldingCNC Machining3D PrintingSheet Metal
Materials by Type
PlasticsMetalsElastomers
Related Links
Customer Supplied ResinsColors
Injection Molding Material Alternatives Guide
Struggling with thermoplastic material shortages? We created a detailed guide to resin substitutes for ABS, PC, PP, and other commonly molded thermoplastics.
Download
-
Resources
Design Tips Guides and Trend Reports Success Stories Design Aids Webinars & Trade Shows
Blog Videos FAQs Educators & Students Glossary
Industries Medical Aerospace Automotive Consumer Electronics Industrial Equipment
-
About Us
Who We Are Why Protolabs? Research and Development Cool Idea Award Partnerships Sustainability & Social Impact
Careers Investors Locations Press Procurement
Contact Us
Proto Labs, Inc.
5540 Pioneer Creek Dr.
Maple Plain, MN 55359
United StatesP: 877.479.3680
F: 763.479.2679
E: [email protected]Best-in-Class Online Quoting
After uploading your part design, you'll receive an online quote that includes manufacturing analysis to help improve part manufacturability. Within your quote, you can also adjust quantity and material and see price changes in real-time.
Learn More
Get a QuoteSign In
Get quality metal 3D-printed prototypes and production parts. Request an online quote today.
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Certifications
ISO 9001:2015 | AS9100D | ITAR Registered
Jump to Section→ Capabilities
→ Available Alloys
→ Compare Material Properties
→ Surface Finishes
→ Post-Processing
→ Why Metal 3D Printing?
Direct metal laser sintering (DMLS) is an industrial metal 3D printing process that builds fully functional metal prototypes and production parts in 7 days or less. A range of metals produce final parts that can be used for end-use applications.
Metal 3D printing technology is commonly used for:
- Prototyping in production-grade materials
- Complex geometries
- Functional, end-use parts
- Reducing metal components in an assembly
We hope you find this guide helpful.
If the file did not download, you can find it here.
Jump start your metal 3D printing with this guide that covers material selection, design, post-processing, and quality inspections.
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Metal 3D Printing Capabilities
Our basic guidelines for metal 3D printing include important design considerations to help improve part manufacturability, enhance cosmetic appearance, and reduce overall production time.
Metal 3D Printing Tolerances
For well-designed parts, tolerances of +0.003 in. (0.076mm) plus 0.1% of nominal length can typically be achieved. Note that tolerances may change depending on part geometry.
Max Dimensions
Layer Thickness
Minimum Feature Size
Tolerances
*At this time, Inconel 718 and Aluminum are the only materials available on our large format, X Line machine
Metal 3D Printing Material Options
Below is our available metal alloys for 3D printing.
Various heat treatments are available depending on material.
Stainless Steel (17-4 PH)
Stainless Steel 17-4 PH is a precipitation hardened stainless steel that is known for its hardness and corrosion resistance. If needing a stainless steel option, select 17-4 PH for its significantly higher tensile strength and yield strength, but recognize that it has far less elongation at break than 316L. Final parts built 17-4 PH receive vacuum solution heat treatment as well as H900 aging.
Primary Benefits
- Heat treated for full hardness and strength
- Corrosion resistance
LEARN MORE>
Stainless Steel (316L)
Stainless steel 316L is a workhorse material used for manufacturing acid and corrosion resistant parts. Select 316L when stainless steel flexibility is needed; 316L is a more malleable material compared to 17-4 PH. Final parts built in 316L receive stress relief application.
Primary Benefits
- Acid and corrosion resistance
- High ductility
LEARN MORE>
Aluminum (AlSi10Mg)
Aluminum (AlSi10Mg) is comparable to a 3000 series alloy that is used in casting and die casting processes.
It has good strength -to-weight ratio, high temperature and corrosion resistance, and good fatigue, creep and rupture strength. AlSi10Mg also exhibits thermal and electrical conductivity properties. Final parts built in AlSi10Mg receive stress relief application.
Primary Benefits
- High stiffness and strength relative to weight
- Thermal and electrical conductivity
LEARN MORE>
Inconel 718
Inconel is a high strength, corrosion resistant nickel chromium superalloy ideal for parts that will experience extreme temperatures and mechanical loading. Final parts built in Inconel 718 receive stress relief application. Solution and aging per AMS 5663 is also available to increase tensile strength and hardness.
Primary Benefits
- Oxidation and corrosion resistance
- High performance tensile, fatigue, creep, and rupture strength
LEARN MORE>
Cobalt Chrome (Co28Cr6Mo)
Cobalt Chrome (Co28Cr6Mo) is a superalloy is known for its high strength-to-weight ratio.
Primary Benefits
- High performance tensile and creep
- Corrosion resistance
LEARN MORE>
Titanium (Ti6Al4V)
Titanium (Ti6Al4V) is a workhorse alloy. Versus Ti grade 23 annealed, the mechanical properties of Ti6Al4V are comparable to wrought titanium for tensile strength, elongation, and hardness. Final parts built in Ti6Al4V receive vacuum stress relief application.
Primary Benefits
- High stiffness and strength relative to weight
- High temperature and corrosion resistance
LEARN MORE>
Compare Material Properties
20 μm = high resolution (HR)
30, 40, and 60 μm = normal resolution (NR)
- US
- Metric
| Materials | Resolution | Condition | Ultimate Tensile Strength (ksi) | Yield Stress (ksi) | Elongation (%) | Hardness |
|---|---|---|---|---|---|---|
| Stainless Steel (17-4 PH) | 20 μm | Solution & Aged (H900) | 199 | 178 | 10 | 42 HRC |
| 30 μm | Solution & Aged (H900) | 198 | 179 | 13 | 42 HRC | |
| Stainless Steel (316L) | 20 μm | Stress Relieved | 82 | 56 | 78 | 90 HRB |
| 30 μm | Stress Relieved | 85 | 55 | 75 | 88 HRB | |
| Aluminum (AlSi10Mg) | 20 μm | Stress Relieved | 39 | 26 | 15 | 42 HRB |
| 30 μm | Stress Relieved | 50 | 33 | 8 | 59 HRB | |
| 40 μm | Stress Relieved | 43 | 27 | 10 | 50 HRB | |
| Cobalt Chrome (Co28Cr6Mo) | 20 μm | As Built | 182 | 112 | 17 | 39 HRC |
| 30 μm | As Built | 176 | 119 | 14 | 38 HRC | |
| Inconel 718 | 20 μm | Stress Relieved | 143 | 98 | 36 | 33 HRC |
| 30 μm | Stress Relieved | 144 | 91 | 39 | 30 HRC | |
| 30 μm | Solution & Aged per AMS 5663 | 208 | 175 | 18 | 46 HRC | |
| 60 μm | Stress Relieved | 139 | 83 | 40 | 27 HRC | |
| 60 μm | Solution & Aged per AMS 5663 | 201 | 174 | 19 | 45 HRC | |
| Titanium (Ti6Al4V) | 20 μm | Stress Relieved | 153 | 138 | 15 | 35 HRC |
| 30 μm | Stress Relieved | 144 | 124 | 18 | 33 HRC |
| Materials | Resolution | Condition | Ultimate Tensile Strength (MPa) | Yield Stress (MPa) | Elongation (%) | Hardness |
|---|---|---|---|---|---|---|
| Stainless Steel (17-4 PH) | 20 μm | Solution & Aged (H900) | 1,372 | 1,227 | 10 | 42 HRC |
| 30 μm | Solution & Aged (H900) | 1,365 | 1,234 | 13 | 42 HRC | |
| Stainless Steel (316L) | 20 μm | Stress Relieved | 565 | 386 | 78 | 90 HRB |
| 30 μm | Stress Relieved | 586 | 379 | 75 | 88 HRB | |
| Aluminum (AlSi10Mg) | 20 μm | Stress Relieved | 268 | 180 | 15 | 46 HRB |
| 30 μm | Stress Relieved | 345 | 228 | 8 | 59 HRB | |
| 40 μm | Stress Relieved | 296 | 186 | 10 | 50 HRB | |
| Cobalt Chrome (Co28Cr6Mo) | 20 μm | As Built | 1255 | 772 | 17 | 39 HRC |
| 30 μm | As Built | 1213 | 820 | 14 | 38 HRC | |
| Copper (CuNi2SiCr) | 20 μm | Precipitation Hardened | 496 | 434 | 23 | 87 HRB |
| Inconel 718 | 20 μm | Stress Relieved | 986 | 676 | 36 | 33 HRC |
| 30 μm | Stress Relieved | 993 | 627 | 39 | 30 HRC | |
| 30 μm | Solution & Aged per AMS 5663 | 1434 | 1207 | 18 | 46 HRC | |
| 60 μm | Stress Relieved | 958 | 572 | 40 | 27 HRC | |
| 60 μm | Solution & Aged per AMS 5663 | 1386 | 1200 | 19 | 45 HRC | |
| Titanium (Ti6Al4V) | 20 μm | Stress Relieved | 1055 | 951 | 15 | 35 HRC |
| 30 μm | Stress Relieved | 993 | 855 | 18 | 33 HRC |
These figures are approximate and dependent on a number of factors, including but not limited to, machine and process parameters.
The information provided is therefore not binding and not deemed to be certified. When performance is critical, also consider independent lab testing of additive materials or final parts.
Surface Finish Options
Standard Finish
Expect roughness values of 200 to 400 µin Ra (0.005 to 0.010mm Ra), depending on material and resolution. Support structures are removed and layer lines are visible.
Custom Finish
We offer brushed surfaces in a range of grits and polished mirror finishes. Be sure to indicate if the custom surface finish is for functional or aesthetic purposes so we can best consult you on our custom options.
Post-Processing Capabilities for Metal 3D-Printed Parts
Improve strength, dimensional accuracy, and cosmetic appearance of final metal components with DMLS for production.
Surface Finishing
- 3- and 5-axis milling
- Turning
- Polish (Mirror or Brushed)
- Passivation
- Wire EDM
- Tapping and reaming
Heat Treatments
- Stress relief
- NADCAP heat treatment
- Hot isostatic pressing (HIP)
- Solution annealing
- Aging
Mechanical Testing
- Tensile
- Rockwell Hardness
Powder Analysis & Material
- Traceability
- Chemistry
- Particle size and distribution analysis
Why Use Metal 3D Printing?
See how metal additive manufacturing technology can be used to reduce components within an assembly, fabricate complex geometries, and ultimately save you time and costs.
Click to enlarge
How Does Metal 3D Printing Work?
The DMLS machine begins sintering each layer—first the support structures to the base plate, then the part itself—with a laser aimed onto a bed of metallic powder. After a cross-section layer of powder is micro-welded, the build platform shifts down and a recoater blade moves across the platform to deposit the next layer of powder into an inert build chamber. The process is repeated layer by layer until the build is complete.
When the build finishes, an initial brushing is manually administered to parts to remove a majority of loose powder, followed by the appropriate heat-treat cycle while still fixtured in the support systems to relieve any stresses. Parts are removed from the platform and support structures are removed from the parts, then finished with any needed bead blasting and deburring. Final DMLS parts are near 100 percent dense.
Large Format Metal 3D Printing
We recently added the GE Additive X Line to our fleet of metal 3D printers to build large Inconel 718 and Aluminum (AlSi10Mg) parts.
Have a project that might be a good fit? Contact us and we can discuss your requirements.
Learn More >
Metal 3D Printing for Production
Improve strength, dimensional accuracy, and cosmetic appearance for end-use metal components with post-processing options like CNC machining and heat treatments.
Learn More >
Resources
Design Tip
Post-Processing for Metal 3D Printing
Learn how to improve dimensional accuracy, surface roughness, and mechanical properties on metal parts with high-requirement applications.
Read Design Tip
White Paper
Combining Part Assemblies with Additive Manufacturing to Reduce Cost and Increase Performance
How to find the right opportunities to consolidate multi-part assemblies into single components with industrial 3D printing
Read White Paper
Blog
Inconel 718: A Workhorse Material for Additive Manufacturing
Inconel 718 is a go-to material for additive manufacturing of metal parts.
Read Blog
Blog
Large Format 3D Printing for Aluminum and Inconel Parts
When you’re printing really large parts in metal, it’s great to have a choice of materials. Aluminum and Inconel 718 both make a lot of sense, but which one is the best for your application?
Read Blog
Instant quotes on 3D-printed parts
Get A QuoteAluminum 3D printing - aluminum-guide.com
Aluminum 3D printing and Alcoa
Fortune magazine reports that aluminum giant Alcoa has invested $60 million to establish a new manufacturing center that will specialize in the development of aluminum 3D printing technology. parts and products for the aerospace and automotive industries.
The new division will develop modern methods for 3D printing of parts and products from aluminum alloys. This center will promote this technology for the manufacture of large-sized products, as well as create new materials - aluminum alloys, which will be better suited for 3D printing.
The amount of funding shows the importance of this innovative area of the aluminum industry - 3D printing of parts and products from aluminum alloys.
What is aluminum 3D printing?
3D printing technology for metals, including aluminum, is more technically called Direct Metal Laser Sintering technology. This technology creates metal, including aluminum, parts and products - prototypes (prototypes) and industrial batches. The essence of this technology lies in the fact that the laser used in it selectively fuses fine metal powder in layers in accordance with the 3D drawing of the product, made using AutoCAD, Solidworks programs or a special program for 3D printing - Autodesk 3ds Max.
For other materials, such as plastics and ceramics, 3D printing is performed by other methods, such as stereolithography, inkjet, extrusion.
What does 3D printing do for the aluminum industry?
Traditional methods of manufacturing parts are to remove the "excess" metal from the workpiece to give it a given geometric shape.
These methods usually involve types of mechanical processing of metals - often in the form of CNC machining, such as milling, drilling, planing, etc. The essence of metal 3D printing technology is the opposite: little by little, layer by layer, metal is added to the part. Therefore, the technology of 3D printing of metal parts has much more possibilities in terms of the complexity of their configuration. In addition, this technology has the ability to produce not just parts, products that consist of several parts.
The thickness of each layer of powder is from 5 to 30 micrometers, the dispersion of the powder is up to 5 micrometers.
Metal 3D Printing Machine
Schematic of a Typical Metal 3D Printing Machine
Aluminum 3D Printing Technology
Step 1 - Feed Aluminum Powder.
The feed piston moves up one layer thickness and feeds the powder in front of the roller.
Step 2 - Adding another layer of powder.
The roller shifts the powder onto the work table.
Step 3 - Sintering.
The laser sinters
aluminum powder exactly within the
cross-section of the part that corresponds to this layer.
Step 4 - Lowering the platform with the part.
Platform with sintered aluminum powder
is lowered by one layer thickness.
Step 5 - Create layers.
The process is repeated until the entire part, layer by layer of
, is laser-created from sintered aluminum powder
Step 6 - Extraction of the finished aluminum part.
The platform with the working table rises and
releases the finished part for its removal.
Why print aluminum parts?
The main advantage of 3D printing of metal parts - direct laser sintering technology - lies in its ability to produce parts that cannot be made with conventional technologies. Using this technology, it is possible to produce parts with complex geometries, long and narrow channels and metal mesh structures. In addition, laser sintering technology can be used to produce assembly units from several parts.
Aluminum Alloy Powder for 3D Printing
It is currently reported that AlSi10Mg and AlSi10Mg0.5 alloys, as well as AlSi9Cu3 alloy, are mainly used for 3D printing of aluminum parts. AlSi10Mg alloy is a cast aluminum alloy, from which castings with complex geometry and thin walls are usually made for the aerospace and automotive industries, including engine parts and housings of various units.
Aluminum 3D Printing Dimensions
Today - the end of November 2015 - manufacturers of aluminum parts and 3D printing products limit the dimensional parameters of these parts to the following conditions.
Maximum dimensions of aluminum parts
Machines for direct laser sintering of metals - 3D printing of aluminum parts most often come in such basic working platform dimensions:
- 100x100x75 mm,
- 140x140x100 mm,
- 250x250x300 mm,
- 400x400x360 mm,
- 500x500x500 mm.
Minimum dimensions of aluminum parts
The minimum dimensions are determined by the condition: the sum of the length, width and height of the part must be at least 30 mm.
The minimum thickness of an aluminum part for 3D printing must not exceed 1.0 mm. The normal thickness is 1.6mm.
Sources:
http://www.shapeways.com
https://www.xometry.com
Aluminum 3d printing technology and industry applications
Aluminum 3D printing is a technology for creating prototypes of aluminum parts and products by layer-by-layer laser sintering, material fusion. With the help of three-dimensional technologies, it became possible to create elements with complex geometry and intricate designs, as well as subassemblies from several parts.
Properties and applications of aluminum in 3D printing
Lightness, softness, ductility, resistance to corrosion are properties of aluminum that have long been appreciated on an industrial scale. This metal has long been successfully used in such industries as aviation, aerospace, automotive, machine tool building, and medicine. Despite active use, the properties of aluminum are constantly being improved.
Why aluminum-based alloys are used rather than pure metal
This material does not have its own safety margin, and therefore, for the functionality of aluminum, it is alloyed with other materials, for example, copper, manganese, magnesium.
Traditionally, stamping, casting, forging, machining on milling machines are used to work with aluminum alloys. These processes are quite laborious, costly, high-waste, and largely outperform 3D printing.
The most common additive technology for working with aluminum
Selective laser melting (SLM) is a technology by which aluminum is 3D printed. Under the action of high-power lasers, the finely dispersed aluminum powder used as raw material is sintered into three-dimensional structures layer by layer. The minimum thickness of the product is usually one millimeter or more, and the thickness of each layer of powder ranges from 5 to 30 micrometers.
Stages of the 3D aluminum printing process
The technological process consists of several cycles:
● a digital model of the product is created on the computer;
● the model is divided into layers;
● The working chamber of the 3D printer is filled with inert gas;
● a thin layer of aluminum powder is applied to the working table;
● The layer is laser-fused according to its digital model;
● then the process is repeated layer by layer.
A feature of 3D modeling for aluminum printing is the growth of support structures from this material. The configuration of support structures is usually unknown initially and is built automatically by the program. The removal of structures during the post-processing of the product is done manually and is a time-consuming and meticulous work.
Advantages of 3D printed aluminum products
Aluminum 3D printing makes it possible to obtain not only complex, but also very accurate prototypes, while significantly reducing the cost of products. Finished products, aluminum parts for industrial use have unique qualities, for example, they allow you to minimize the weight and volume of structures, their total cost.
Conventional technology has largely held back the prospects for the use of aluminum alloys in industry. Even the most advanced methods of casting and milling aluminum do not allow the creation of high-precision and ultra-thin designs. Additive technologies, on the other hand, not only cope with such tasks, but also open up a number of new opportunities.
