What is metal 3D printing? What do the most important advantages result from and where is metal 3D printing actually used effectively today?
In this blog article, find out in which industries metal 3D printing is used and what the basic functions of the respective metal 3D printing processes are. By comparing it with “traditional manufacturing” the following advantages can be derived, which shed light on the current status and potential opportunities of the technology.
Metal 3D Printing – How it works
Metal 3D Printing can be used to produce objects by adding material layer by layer based on digital 3D construction data (CAD file). This is where the term Additive Manufacturing (AM) comes from.
High-precision objects with complex geometries can be produced automatically based on the technology of the layer construction principle. In comparison to traditional manufacturing methods, such as subtractive (CNC machining) or molding (metal casting), these do not require any special tools (e.g. a mold) to be implemented.
The work steps of additive manufacturing are divided into 3 main processes. In the pre-process, preparations are carried out before the actual printing process of the object (in-process). After printing, there is post-processing, which includes, for example, the removal of supporting structures or surface refinement. The post-processing step is usually not eliminated.
Traditional Metal Manufacturing
In addition to metal 3D printing, there are other traditional manufacturing methods that we would like to briefly explain below.
Subtractive Manufacturing
Subtractive manufacturing is one of the traditional methods of metal production. Here, a shape is carved out of a larger metallic starting block or blank. This is done by removing material from the metal block in a controlled manner by turning, milling, grinding or drilling manually or using CNC machining.
Formative Manufacturing
Formative manufacturing does not involve removing metal from the source material or adding material, but rather forming or modeling a given volume using heat and/or pressure. This includes casting technology and pressing technology. Typical examples of this production include casting, stamping or forging.
Metal 3D Printing Applications
Metal 3D printing is primarily used in those industries in which complex geometries, high personalization, precision and attention to detail are particularly important.
These requirements exist, for example, in medical and dental technology (prosthetics), but also in the automotive industry, aerospace or tool and mechanical engineering (additive tooling and prototype construction).
Healthcare (Medical and Dental Technology)
Metal 3D printers have the ability to create complex structures based on an individual’s anatomy. This makes 3D metal printing particularly interesting for the medical and dental industries, which is why today mainly customized prostheses and implants made of biocompatible materials (e.g. titanium) are printed.
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- 3D printed metal bridges by 2onelab
Aerospace
The aerospace industry benefits from the continuous development of 3D printing. What is particularly essential for this industry is lightweight construction, which is characterized, for example, by internal structures and undercuts. 3D metal printing simplifies the production of these components and enables a significant reduction in weight and cost of production, while at the same time maintaining high stability and quality.
Automotive Industry
Metal 3D printing was also able to quickly find application in the automotive industry as a way to produce end products. High-performance and racing vehicles are currently the main applications of 3D metal printing.
Tool and Mechanical Engineering (Rapid Tooling & Prototyping)
3D metal printing is now also used for the production of tools and tool components as well as mold making (Additive Tooling or Rapid Tooling). These are also used in “traditional metal production”. Examples: sand casting, investment casting.
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- 3D printed metal cooling nozzel by 2onelab
With Rapid Prototyping, 3D metal printing can be used to produce complicated prototypes, small series or customized products quickly and cost-effectively. This process is used in mechanical engineering, aerospace, the automotive industry, but also in healthcare or architecture.
Advantages of 3D Metal Printing
Advantages of metal 3D printing compared to traditional metal manufacturing
Traditional metal manufacturing, such as subtractive manufacturing (CNC machining) or formative manufacturing (metal casting), has its own advantages and uses. However, metal 3D printing offers significant advantages that offer particular added value for certain industries.
- Complex Geometries
With metal 3D printing, the production of such complex, delicate structures is possible, which is not possible for traditional production. - High Accuracy and Personalization
The creation of extraordinarily precise productions with simultaneous robustness, lightness and quality is possible. Added to this is the high level of personalization (CAD file). - Cost Efficiency and Time Savings
Better cost efficiency is achieved by not assembling objects from several individual parts, as before, but by creating them from just one piece. This reduces manufacturing costs as well as manual work, which in turn saves time. - Independence from the Place of Production
3D metal printers work via a digital interface, which means they can be used decentrally and regardless of location (cloud producing). - Environmental Friendliness
Metal 3D printing and sustainability are not mutually exclusive. This offers better energy efficiency, reduced transport routes and raw material waste or raw material requirements.
Advantages of 2Create & 2Create Plus
2Create with its big brother 2Create Plus offer all the advantages of metal 3D printing and also impress with the following features.
Advantages at a glance:
- Made in Germany
- Easy to Use
- Material Versatility
- Fast Material Change
- Instant Printing
- Short Production Times
- Cost Effectiveness
- Optimal Customer Support
3D Printing Processes with Metal
Find out more about the most common 3D metal printing processes below with further information about the specific functions.
Powder Bed Fusion
With Powder Bed Fusion, metal powder particles are selectively melted together using high-performance lasers (DMLS/SLM) or electron beams (EBM), so that the metal object is created layer by layer. We use laser beam melting in our 3D metal printers 2Create and 2Create Plus.
Valuation: Powder Bed Fusion is currently the most accurate way to produce 3D components for end products. Lengthy, downstream sintering processes are no longer necessary and the component with the optimal density and precision is ready after printing.
Metal Binder Jetting
During Metal Binder Jetting process, a metallic powder is bonded in layers with a liquid binder according to a CAD model. The resulting “green” part is then thermally reworked (debinding) to remove the binder and compacted (sintered) to obtain the finished metallic workpiece.
Valuation: The actual printing process is quick, but a lot of time, up to 24 hours, is required for the processes of debinding and sintering the green part. A major disadvanatge is the low tolerance accuracy, as the components shrink considerably after the sintering process, resulting in a loss of dimensional accuracy.
Metal Material Extrusion
In metal material extrusion, a filament or rod made of polymer and metal powder is melted and extruded through a nozzle onto a platform in order to build up the blank in layers (FDM process). This is then post-processed (debinding and sintering), which creates the all-metal workpiece.
Valuation: As with metal binder jetting, the MME process requires a lot of time for debinding and sintering. In addition, there is also a low tolerance accuracy here, which leads to a loss of dimensional accuracy after the sintering process.
Directed Energy Deposition (DED)
Directed Energy Deposition is often used in combination with metals (powder or wire) for surface finishing or for repairing and modifying existing components. Depending on the process, the material is melted using a laser, an electric beam or a plasma source.
Valuation:The disadvantage here is that the process is not suitable for producing new objects, but is excellent for repairing components
Ultrasonic Additive Manufacturing (UAM)
In Ultrasonic Additive Manufacturing (UAM), metal foils are melted layer by layer using ultrasonic welding and brought into the desired shape using CNC machining.
Valuation:Certain metal combinations are not suitable for the UAM process because of problems with the layer bonding. In addition, not all metals are suitable for the process, which limits the choice of materials.
As listed above, there are various metal 3D printing processes that are specifically selected according to the desired requirements. The predominant 3D printing processes with metal today include: Powder Bed Fusion (DMLS/SLM and EBM), followed by Binder Jetting and Metal Extrusion.
Metals for 3D Printing
Metals for 3D printing are used in different initial forms and compositions (powder, wire, liquid, filament) to create objects. A significant advantage over traditional metal production is that 3D metal printers can process high-strength materials such as nickel or cobalt-chrome superalloys very well.
The metals and metal alloys stainless steel, titanium, aluminum, cobalt chrome and Inconel are best suited for most industrial applications. From aerospace to medical technology. It is noteworthy that the materials available for metal 3D printing are constantly growing. This speaks for the spread and further development of the technology.
- – Stainless Steel (17-4PH or 316L) and Tool Steel have high wear resistance and hardness, as well as good ductility and weldability.
- – Titanium alloys are particularly corrosion-resistant, biocompatible, have a very good strength-to-weight ratio and have low thermal expansion.
- – Aluminum alloys have good mechanical and thermal properties, low density and hardness, and good electrical conductivity.
- – Cobalt-chrome alloys have a very high hardness, are particularly wear-, heat- and corrosion-resistant and biocompatible.
- – Nickel-based superalloys (Inconel) have very good mechanical properties and are particularly corrosion and temperature resistant, which is why they can be used in extreme environments.
- – Copper-based alloys have high temperature and conductivities, have high tensile and yield strength and are particularly corrosion-resistant.
- – Precious metals such as gold, silver and platinum or exotic metals (palladium, tantalum) can be processed with 3D metal printers, but are mainly used in jewelry production.
Conclusion – Metal 3D Printing
Alongside plastic printing, metal 3D printing is one of the most important additive manufacturing processes based on the layered construction principle.
Traditional metal production methods, such as subtractive or formative manufacturing processes, have their own advantages and applications. Compared to these, 3D printing with metal offers significant advantages that are particularly interesting for certain industries in terms of accuracy of fit, complex shapes, high customization options and small batch production.
These include the healthcare sector (prosthetics in medical and dental technology), aerospace, the automotive industry and toolmaking and mechanical engineering. One example of medical technology is custom-fit titanium hip implants for patients.
Today, metal 3D printing has already proven itself in many industries due to these advantages and offers considerable opportunities for efficient further development and use in other areas in the future.
FAQ: Metal 3D Printing
Can 3D printers print metal?
3D metal printers are specially designed machines that receive information for creating an object (CAD file) via software instructions. Based on this design data, the respective layers are layered with the metal material, for example using a laser (SLM process).
How does metal 3D printing work?
Metal 3D printing is part of additive manufacturing and is characterized by the fact that layers of an object are built up layer by layer. This can be done, for example, by melting metallic powder using a laser (SLM process).
How does metal 3D printing differ from conventional methods?
In subtractive metal production, material is removed from a block in a controlled manner until the desired shape is achieved. Machining methods can be: Turning, milling, grinding and drilling manually or by CNC machining.
Material is neither added nor removed during formative production; the initial mold is reshaped using a casting or pressing technique. E.g. casting or forging.
What are the advantages of additive manufacturing with metal?
Metal printing processes offer the following advantages compared to traditional metal manufacturing processes: the creation of very complex geometries, high precision and customization options, lightness, cost efficiency and time savings, reduced Co-2 emissions and less material consumption and waste.
Our two metal 3D printers, 2Create and 2Create Plus, are based on laser beam melting (SLM) and impress with their high accuracy, precision, speed, efficiency, material versatility and cost-effectiveness, making them ideal for a wide range of applications.
In which areas are metal 3D printing applications used?
Industries whose manufacturing processes require a high degree of customization, complex structures and cost efficiency benefit particularly from 3D metal technology.
Characteristic industries are: medicine (prosthetics in medical and dental technology), aerospace, the automotive industry as well as toolmaking and mechanical engineering.
What are the best-known 3D metal printing processes?
There are various metal 3D printing processes that can be considered depending on the manufacturing objectives. The predominant processes today include Laser Powder Fusion (DMLS/SLM and EBM), followed by Metal Binder Jetting and Metal Extrusion.
What metals can be 3D printed?
Metals that are printed into an object using the layering process (3D printing) can be available in different material compositions (powder, wire, liquid, filament).
Frequently used metals for industrial applications are Stainless steel, tool steels, titanium alloys, aluminum alloys, nickel-based superalloys, cobalt-chromium alloys, copper-based alloys.
Precious metals (e.g. gold, silver, platinum) and exotic metals (e.g. palladium and tantalum) are also processed in jewelry production.
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Author: Markus Wolf
Passionate about 3D printing, while being
CTO and Co-Founder of 2oneLab.
