3D printers are enjoying increasing popularity. In our 3D printing series over the past few weeks, we have informed you about
Today we want to turn our attention to the topic of metal in 3D printing. Because 3D printing with metal has made significant progress in recent years and opens up a variety of possibilities in various areas. In this blog post, we will explain the most important things you need to know about 3D printing with metal. And as always, we have a little surprise for you at the end of the post.
Your first models with metal were a complete success and you would like to delve deeper into the world of 3D printing?
What is 3D metal printing?
3D metal printing, also known as additive manufacturing, is a process in which metal powder is applied layer by layer and melted by means of a laser or electron beam (laser melting). This is how you create three-dimensional objects. Unlike traditional plastic 3D printing, which is mainly used for prototypes and simple components, 3D metal printing produces high-strength, durable components for demanding applications. The results also differ significantly in terms of shape, strength and weight.Areas of application
3D metal printing is used in a variety of industries:- Industry: In aerospace and the automotive industry, complex, lightweight components are produced by 3D printing that cannot be manufactured traditionally.
- Medicine: Metal 3D printing enables the production of customized implants and prostheses that are perfectly matched to the patient and adapt to them. Dental implants and hip prostheses are prominent examples here.
- Jewelry and Design: Designers sometimes use the technology to create delicate and complex pieces of jewelry that would be difficult to realize with conventional methods.
- Research and Development: In laboratories and research institutions, metal 3D printing is used to develop new materials and technologies.
Technologies and processes
There are various technologies in metal 3D printing, each with its own advantages and disadvantages:- Direct Metal Laser Sintering (DMLS): In Direct Metal Laser Sintering, metal powder is fused layer by layer with a laser. This method is well suited for complex geometries and has a high material diversity.
- Selective Laser Melting (SLM): Similar to Direct Metal Laser Sintering, but here the powder is completely melted, which leads to denser and stronger parts. SLM is often used in aerospace and medical technology.
- Electron Beam Melting (EBM): Uses an electron beam instead of a laser. EBM is faster and suitable for large parts, but requires a vacuum environment.
- Binder Jetting: Metal powder is glued with a binder and then sintered. Sintered (comes from the word sinter) means that the fine-grained metal powder is heated at high temperatures, but below the melting point, to bond the particles together and form a solid, dense object. This method is faster and more cost-effective, but the parts often require post-processing.
Materials in metal 3D printing
Here is an overview of the most commonly used metals and alloys in 3D printing:- Aluminum: Aluminum is a lightweight and corrosion-resistant material, ideal for aerospace and the automotive industry.
- Titanium: Titanium is a material with high strength and low weight. And it is biocompatible, therefore widely used in medicine and aerospace.
- Stainless steel: Robust, corrosion-resistant and versatile in many industries.
- Nickel alloys: Excellent resistance to high temperatures and corrosion, often used in the energy and chemical industries.
The process in metal 3D printing
The process usually includes the steps described below:- Preparation of the print file: The object to be printed is designed with CAD software and converted into a printable format (e.g. STL).
- Selection and preparation of the material: The metal powder is selected and prepared for the printing process.
- Printing process and monitoring: The metal powder is applied layer by layer and melted by means of a laser or electron beam.
- Post-processing: After printing, the parts are often heat-treated to relieve stress and mechanically processed to achieve the desired surface qualities.
Advantages and challenges of metal 3D printing
Metal 3D printing offers numerous advantages:- Design freedom: You realize complex geometries.
- Material savings: You reduce waste because you only use the necessary material due to the layer-by-layer construction.
- Rapid prototyping: You shorten development times for new products.
- High costs: The acquisition and operation of metal 3D printers are expensive. The technology for metal 3D printing, especially sintering, is somewhat more complex and not quite as easy to implement, especially for beginners.
- Technical limitations: Not all geometries and materials are suitable, and the printing speed is sometimes often slower than with traditional methods and other materials (powder, filament).
- Post-processing: The printed metal part often requires extensive post-processing to achieve the desired mechanical properties and surface qualities.
Further information
Your first models with metal were a complete success and you would like to delve deeper into the world of 3D printing?
- You are already an expert and would like to become a 3D printing expert and learn everything there is to know about it?
- You remembered the surprise in the introduction of this article and are curious what it could be?
