Metal 3D printing is becoming a common manufacturing process in most industries. This is a guide to the metal 3D printing process, some benefits and challenges, as well as its popular applications.

Metal 3D Printing Prototype Technology

The working principle of metal 3D printers is the same as other 3D printers. Basically, it builds parts by adding materials layer by layer. This is after referencing CAD files or 3D designs. The three commonly used techniques in metal 3D printing are DMLS/SLM, metal extrusion, and adhesive spraying.

DMLS/SLM Metal 3D Printing Prototype

SLM stands for Selective Laser Melting. This is an example of a rapid metal prototyping method. The metal 3D printing method melts and fuses metal powders together with the help of high-power density lasers. It performs this operation layer by layer, ultimately forming a component. However, DMLS stands for direct metal laser sintering and has some similarities with SLM. The only difference is the laser temperature. DMLS does not completely melt metal powder.

Metal extrusion

This process is relatively new for the additive prototyping industry. It has some similarities with the equally popular FDM technology. Firstly, we heat the filament and then extrude it through a nozzle, depositing it layer by layer. The filament contains metal particles and thermoplastic materials. Finally, to manufacture fully functional metal parts, we need to perform post-processing on them. Methods such as sintering and bone removal.

Adhesive spraying

This metal 3D printing process uses two materials. They are adhesives and powder based materials. Adhesives are used to bond deposited powder based materials. Therefore, its function is like a glue between powder layers. However, it also requires a heat post-treatment process, such as sintering, to make it a complete component. This process removes the adhesive.

How does metal 3D printing work?

The common manufacturing methods used are similar to SLM and DMLS. Here we will focus on the working principle of metal 3D printing. Firstly, we fill the construction chamber with an inert gas (such as argon). It reduces the chance of oxidizing metal powder, allowing us to manufacture parts at the optimal temperature. Next, we apply a thin layer of metal powder on the building platform. Then, the high-power laser scans the cross-section of the component. This melts and fuses the metal particles together, forming the next layer. We scan the entire area of the model to create a fully solid part. After scanning is completed, the platform moves down one layer of thickness. Then we apply a thin layer of metal powder again. We repeat this process to make the entire component.

The benefits of metal 3D printing prototypes

Metal 3D printing has some unique advantages in the manufacturing and prototyping of metal parts.

Enhanced component functionality

Metal 3D printing makes it possible to manufacture the internal structure of parts. This improves the overall performance of the manufactured parts. For example, we can manufacture injection molds with internal channels. This helps with cooling, thereby reducing the number of injection cycles. In addition, with the help of metal extrusion technology, we can produce fixed devices and fixtures for complex geometric parts.

Excellent material properties

Parts made through metal 3D printing technology have strong material strength. Compared to forged metal, printed parts are much better. Therefore, it makes this method an ideal choice for the most demanding industries such as aerospace.

Geometrically complex design

Metal 3D printing has extraordinary flexibility in design. It can handle complex geometric shapes without any problems. Surprisingly, this flexibility did not translate into higher costs. Therefore, you can obtain metal parts with complex geometric shapes that cannot be achieved by other processes.

What are the challenges of metal 3D printing? Although metal 3D printing has significant advantages, it does have some limitations that affect its prototyping capabilities.

Need post-processing

In order to obtain fully functional parts, some post-processing is required. All metal 3D printing technologies are like this. For example, processes such as mechanical processing, polishing, and heat treatment. Therefore, it increases production costs and extends delivery times.

The mass production capacity of metal 3D printing is limited

Metal 3D printing can only produce efficient parts on a small scale. However, the industry is trying to figure out how to simplify 3D printing systems when producing more parts.

What is the application industry?

Medical industry

Metal 3D printing has extraordinary capabilities in manufacturing organic like structures. This makes it an ideal choice for the healthcare industry. Medical implants made from biocompatible materials such as titanium come from this process.

Automotive industry

The industry has adopted metal 3D printing to manufacture high-performance parts. For example, racing parts require high impact resistant parts with a high strength to weight ratio.

Aerospace industry

Metal 3D printing has enormous potential in serving the industry well. Aerospace components require geometrically complex lightweight parts. Therefore, this process is highly suitable as it meets these requirements.