Here's what you need to know.
3D printing metals has come a long way, and lately it's been trending in the news.
Additive Manufacturing Research (AMR) predicts a strong future for the metal additive manufacturing (AM) sector, driven by sectors like aerospace, automotive, and healthcare. The report identifies defense spending and industry consolidation as potential factors that could further boost the market.
Metal 3D Printing Market Set to Grow to $5.4B in 2023, Says AM Research Report Source 3dPrint.com
Image source ptc.com
A brief history of 3D printing metals.
The history of additive manufacturing, particularly in the context of 3D printing metals, is a tale of technological innovation and steady progression over several decades. It all began in the early 1980s when Dr. Hideo Kodama, a Japanese engineer, first conceptualized the layer-by-layer additive manufacturing process. His work laid the foundation for what we now know as 3D printing. However, the initial focus was primarily on polymers and plastics.
The breakthrough into metal 3D printing came later in the 1990s when researchers and engineers started experimenting with using metal powders and lasers to create intricate metal parts. One of the key milestones in this journey was the development of a technology called Selective Laser Sintering (SLS), which allowed for the fusion of metal powders into solid metal objects layer by layer. In the early 2000s, various other metal 3D printing techniques such as Direct Metal Laser Sintering (DMLS) and Electron Beam Melting (EBM) emerged, each with its own advantages and limitations.
Over the years, advancements in materials science, laser technology, and precision engineering have significantly expanded the capabilities of metal 3D printing. This technology has found applications in diverse industries, including aerospace, automotive, healthcare, and more, due to its ability to produce complex, lightweight, and customized metal components with high strength and precision. Today, metal 3D printing is a rapidly growing field, and it continues to evolve, paving the way for groundbreaking innovations in manufacturing and design.
Current available technologies and their benefits
So what are the options we have today? Here are the most common technologies to 3D print metal alloys.
Selective Laser Melting (SLM)
Pros:
High precision and resolution.
Capable of producing complex geometries.
Suitable for producing high-strength, fully dense parts.
Wide range of metal materials available.
Cons:
Relatively slow process.
High equipment and operational costs.
Requires post-processing to remove support structures.
Electron Beam Melting (EBM)
Pros:
High build rate.
Capable of producing fully dense parts.
Less residual stress due to high-temperature processing.
Suitable for titanium alloys.
Cons:
Limited material options.
Requires vacuum conditions, leading to high energy consumption.
Surface finish may be rough and require post-processing.
Direct Metal Laser Sintering (DMLS)
Pros:
Capable of producing complex and detailed parts.
Wide range of metal materials available.
Less waste compared to traditional manufacturing methods.
Cons:
High equipment and operational costs.
Parts may have residual stresses and require heat treatment.
Surface finish may be rough.
Binder Jetting
Pros:
High build rate.
Suitable for producing large parts.
No need for support structures, reducing post-processing efforts.
Cons:
Parts may have lower mechanical properties due to binder presence.
Requires post-processing to remove binder and infiltrate with a metal.
Limited material options.
Metal Extrusion (Metal FDM)
Pros:
Relatively low equipment cost.
User-friendly and easy to operate.
Suitable for producing prototypes and tooling.
Cons:
Limited resolution and accuracy.
Limited material options.
Parts may have lower mechanical properties.
Directed Energy Deposition (DED)
Pros:
Capable of adding material to existing parts (cladding).
Suitable for repairing and modifying metal parts.
Wide range of metal materials available.
Cons:
Limited resolution.
Not suitable for producing small and intricate details.
Requires post-processing for surface finish.
Cold Spray Technology
Pros:
Low-temperature process, reducing thermal stresses.
Suitable for temperature-sensitive materials.
Can be used for coating and repairing parts.
Cons:
Limited to materials with low melting points.
Not suitable for producing complex internal structures.
Surface finish may be rough.
Laminated Object Manufacturing (LOM)
Pros:
Low operational costs.
Suitable for producing large parts.
Minimal waste generation.
Cons:
Limited accuracy and resolution.
Limited material options.
Requires post-processing to remove excess material.
Which is your technology of choice and what is it best for? Tell us in the comments!