5 Types of Metal 3D Printing Processes and Their Materials

Metal 3D printing, or additive manufacturing, has transformed the manufacturing and prototyping industries by enabling the making of complex, high-performance metal parts. Unlike traditional methods that involve cutting away material, metal 3D printing builds parts layer by layer, enabling a higher level of precision and design freedom. With many different metal 3D printing processes available, companies can now manufacture metal parts and components tailor-made for industries running from aerospace to automotive. In this article, five common types of metal 3D printing processes will be discussed along with the materials used in each process.

1. Selective Laser Melting (SLM)

Among the most popular methods in the category of metal 3D printing is Selective Laser Melting. It involves the melting of metal powder by a laser with high power to produce the final part layer by layer. SLM offers highly detailed parts that are very strong with impressive mechanical performance.

Materials: So many metals, as well as titanium alloy, stainless steel, aluminum, and Inconel, are usually used with SLM. Such metal powders have an outstanding strength-to-weight ratio coupled with high-temperature resistance; hence, those metals are ideal for the aerospace and automotive industries. 

SLM is best suited for a custom metal 3D printing because it allows for the production of complex geometry designs that would be too difficult or even impossible to achieve with the conventional manufacturing techniques. Therefore, if you require parts that are specific, SLM is an attractive solution because it minimizes tooling costs and reduces time periods in bringing products to market.

2. Electron Beam Melting (EBM)

EBM or Electron Beam Melting is a powder bed fusion processing method similar to SLM, where instead of laser, an electron beam is used in the melting of metal powder. This process is mainly applied for part production in the aerospace, medical, and defense sectors, as it allows the fabrication of parts that are dense and high-performance.

Materials: EBM is typically used for titanium alloys such as Ti-6Al-4V, which are preferred for their strength, low weight, and biocompatibility. This means that it can be particularly useful when custom machining parts where titanium is needed for its special properties. Parts made under electron beams are some high density form and free of oxidation, enhancing strength due to the high-energy electron beam working in a vacuum. Less residual stress, which is paramount in heavy industries, is another added advantage of manufacturing by EBM.

3. Direct Energy Deposition (DED)

The term Direct Energy Deposition (DED) basically refers to a form of metal 3D printing, wherein the remelting of metal feedstock onto a substrate is done with a focused energy source such as laser or electron beam. Indeed, such a process is considered extremely flexible and therefore parts can be highly customized, repaired, or modified.

Materials: Various materials can be processed in DED, including stainless steels, titanium alloys, Inconel, and cobalt-chrome alloys. These materials are commonly chosen for their corrosion and heat resistance and mechanical properties. 

In addition, DED is often used for its custom machining, since it adds material to existing components for repairs and/or modifications of the design while circumventing the requirement of complete re-manufacturing.

4. Binder Jetting

Binder Jetting is defined as a metal 3D printing process in which a liquid binder is selectively deposited over metal powder to create a part. After the entire part is printed, it is put into a furnace for sintering so that the metal particles fuse to form a solid structure. It is generally used for low-to-medium production runs.

Materials: Some of the most common binder jetting materials are stainless steel, copper, and tool steel, and the choice of material is very often driven by the need for less stressed but strong and durable components under high loads.

For example, one of the advantages of binder jetting when used for metal 3D printing services is the ability to print parts having complex geometries. Such features ensure that industries do not have to go through the hassle of getting custom parts made for small prototype runs or low production volumes.

5. Metal Extrusion (Fused Deposition Modeling for Metal)

Metal extrusion or Metal Fused Deposition Modeling (FDM) is the same as the normal plastic FDM, except that in place of the thermoplastic filaments, metal filaments are used. These filaments are a mixture of metal powders and binding agents and are extruded through a heated nozzle, layer by layer, to give rise to the desired part.

Materials: Metal extrusion is capable of being conducted on different materials like stainless steel, bronze, and aluminum. The materials are often a compromise between the requirements of the part (strength, ductility, and cost). Custom metal 3D printing for low-volume production or for parts to be used in post-processing is common with this method. The metal extrusion method also offers large-scale production, making it a flexible choice for companies providing metal 3D printing services.

Conclusion

While SLM, EBM, DED, Binder Jetting, and Metal Extrusion process their metals for 3D applications, each has its unique advantages given the material properties, complexities of the parts, and end-use applications. If you want to produce custom machined parts for applications in aerospace, automotive, or medical fields, it has been found that metal 3D printing can now be used to achieve flexibility and high precision with which modern manufacturing is expected. Contact us for the appropriate 3D printing method and material to manufacture high-performance parts for their specific applications.

 

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