Is it possible to 3D print metal? What is metal 3D printing? How does it work? Are all metal 3D printers the same? The following covers the basics on metal AM, including powder bed fusion (PBF) where Direct Metal Laser Sintering / Direct Metal Laser Melting ( DMLS / DMLM), Electron Beam Melting (EBM), Selective Laser Melting (SLM) are a subset, of which how these relate to advantages and limitations compared to other options.
What 3D printing process can be used to 3D print metals? Powder bed fusion holds the market share for metal 3D printers, at 54% according to Aniwaa in 2019. This is followed by Direct Energy Deposition at 16% and Material/ Binder jetting at 16%. Direct Metal Laser Melting and Selective Laser Melting are some of the metal 3D printing processes that fall under Powder Bed Fusion. Both technologies user a laser to scan and melts the metal powder to build a part layer by layer. Direct Metal Laser Sintering has the key difference where the powder is composed of materials with variable melting points that fuses together at elevated temperatures.
Due to the market proliferation of these metal 3D printers and research done , it is no surprise the DMLM, SLM and DMLS is most used in industrial applications for the manufacture of repeatable, end-use engineering products. Other technologies such as Laser Metal Deposition have advantages of one-off manufacturing and are priced accordingly or require significant post-processing to get to acceptable surface finishes and required tolerances.
Additive Engineering utilises GE Additive Concept Laser machines. For Direct Metal Laser Melting, the build chamber is filled with inert gas to minimise oxidation and is heated to build temperatures.
Read about how Air Liquide’s purity of Argon gas helps improve the quality of Additive Engineering’s metal 3D printed products for biocompatible applications in Manufacturer’s Monthly.
Not every metal printing 3D systems is created equal. To the undiscerning, all 3d metal printing solutions looks the same. However, there are specific technologies that have proven to be reliable in manufacturing medical parts and certified airworthy aerospace metal parts. Why should this matter especially for non medical or aerospace products? A key challenge with many 3D metal printing processes is repeatable consistency to become a manufacturing process. While all technologies can manufacture one-off parts (especially metal 3D printing filament processes), the ones that can manufactured consistent 3D printed metal parts are the well-researched, proven metal additive manufacturing processes that would be best suited to support traditional manufacturing as sustainable production solutions.
Process parameters of metal 3D printing technology is usually set by the machine manufacturer. However Additive Engineering has the ability to change digital metal process parameters for improved builds of complex geometry as well as enhancing mechanical properties of a 3D printed part. 3D printing metal parts have dimensional accuracy of approximately +/- 0.1mm.
Biocompatible + Aerospace grade
Biocompatible + corrosion resistant (Aero, tools)
3D printed injection mould tool
Creep-rupture strength ( Aero, Auto & Tools)
Acid + corrosion resistant ( Medical & Aero)
High thermal conductivity
Titanium Ti6Al4V Grade 23 is biocompatible for medical implants and is also used in the manufacture of blades, gearboxes and engine parts.
Inconel Nickel 718 has minimal deformation over time as load under maximum capacity is applied with extreme temperatures, and is used in electric car battery packs, manifolds, heat exchangers, aviation tools and space components.
Titanium Ti6Al4V Grade 23 is biocompatible for medical implants and is also used in the manufacture of blades, gearboxes and engine parts.
Inconel Nickel 718 has minimal deformation over time as load under maximum capacity is applied with extreme temperatures, and is used in electric car battery packs, manifolds, heat exchangers, aviation tools and space components.
Traditional antenna manufacturing consists of complex large and heavy systems which could lead to higher launch costs and inconsistent radio frequency (RF) performance at higher frequency bands. Utilising DMLM, Optisys consolidated 100 parts into one part, reducing leadtime from 11 to 2 months and reducing component weight by consolidating 100 parts into 1 part, reducing lead time from 11 months to 2 months, reducing weight by 95% and size by 80%.
Have a similar requirement for your project?
Additive Engineering is a member of the Advanced Manufacturing Growth Centre (AMGC). Our team is experienced in rapid prototyping, conventional manufacturing for production parts such as CNC machining, injection moulding, vacuum casting and a range of 3D printing / additive manufacturing technologies that have been tried and tested in aerospace airworthy parts as well as medical devices.
Whether your requirements involve one prototype, transitioning from traditional manufacturing processes or 3D printing a complex lattice structure, the Additive Engineering team has the expertise in both traditional manufacturing methods and additive manufacturing processes to advise on the optimal manufacturing method for your parts.
To meet the stringent requirements of both medical, electronics and aerospace customers, the facility set up is modelled to manufacture parts in a clean-room environment with the objective to meet the highest standards as required by industries.
Additive Engineering utilises industry proven 3D printers such as EOS and GE Concept Laser printers to 3D print repeatable products with high surface quality and outputs the finest part structures. The Additive Engineering team can assist you in improving design for additive manufacturing in complex components that are too difficult and costly to manufacture using subtractive manufacturing methods.
Simplified delivery for ready to use products.
Drawing on our extensive knowledge in materials from GE to our industry experience in the medical industry, we combine design, simulation, additive manufacturing, heat treatment, testing, sterilisation and packaging to ensure the complete part is delivered, ready to be used.
