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Do you want to 3D print metal parts? Whether you're a 3D printing enthusiast or a professional whose work involves 3D printing, learning to 3D metal parts will increase the opportunities available to you. Below, we discuss how metal 3D printing works, the technology available for metal 3D printing, and how you can 3D print metal parts with your home 3D printer.
Technology for 3D Printing with Metal
3D printing technology has come a long way in the past few years. Just a few years ago,3D printers were limited to using thermoplastics and resins. Today, you can now purchase a 3D printer designed to print with metal specifically. There are various technologies available for 3D printing with metal. These are categorized based on whether the printing uses metal powder, metal filament, or metal wire. Other popular technologies for 3D printing with metal use metal rods, metal pellets, and resins infused with metal as materials.
The technology used for 3D printing with metal will dictate what you can achieve with your prints. You should therefore consider factors such as the details, size, shape, strength as well as type of metal you intend to print with when considering different technologies. The most popular technologies used for 3D printing with metal include:
- FDM
Fused deposition modeling (FDM) printing is one of the most popular 3D printing technologies with other materials. It is also quite popular with 3D printing metals. Like with plastics, FDM printing with metals uses filaments. The filaments feature a plastic base that has been infused with metal particles. Many high-quality metal filaments used to 3D print metal parts contain a high percentage of metal powder, i.e., about 80 percent. During the post-processing stage, the plastic component is removed. The metal part is then condensed. Some of the most common metal filaments currently on the market include titanium, stainless steel, and copper.
FMD printing is suitable mostly for making small parts such as metal nozzles. The post-processing is often done by a third party and is quite involving. Printing larger parts would be an extremely expensive and slow process.
- SLM
Selective laser melting (SLM) involves the use of high-powered lasers to melt the metal powder. Most of the 3D printers designed specifically 3D print with metal rely on this technology. The laser selectively melts the powder layer by layer. The molten layers fuse together on a molecular level to form a homogenous model.
- EBM
Electron Beam Melting (EBM) is similar to SLM 3D printing technology. However, this technology uses an electron beam as a source of energy. The printing process is carried out in a vacuum. The electron beam is directed to a container filled with metal powder. This method of 3D printing with metal is much faster than SLM.
This printing process is great for achieving intricate details. For example, it has been applied to the printing of hip and knee implants made from titanium. Manufacturers are better able to produce high-quality parts that meet the high government standards for medical implants.
There are various other technologies available for 3D printing with metal. However, they are restricted to application in industrial settings, which is outside the scope of this blog.
How to 3D Print with Metal
As mentioned previously, there are some manufacturers today that sell 3D printing filament that is infused with metal dust. Some of these filaments are designed to only imitate metal in appearance. We are not talking about printing with these types of filaments. We are instead looking at 3D printing to produce all metal parts. To achieve this, a 3D printing filament that contains a large amount of metal dust must be used. There are several manufacturers that produce metal filaments which consist of about 80 percent of metal dust.
The printing process using metal filaments is similar to using other types of filaments. However, you will need to ensure that your printer can actually achieve the conditions required for successfully printing with this filament.
You should ensure that you have a steel nozzle. Steel is a tough material. It is resistant to abrasion. Therefore, it is the best option when 3D printing with metal. You should also ensure that your printer can achieve high temperatures (around 250 degrees centigrade). Metal filaments cool quickly. This can interfere with the adhesion of the layers. You should therefore invest in a heated bed if you don't already have one. Your printer should also be able to print at high speeds. This will ensure better quality results.
Post Processing of 3D Printed Metal Parts
The post-processing state is important in 3D printing with metal. It is in this stage that you will achieve all-metal products. This part of the 3D printing process involves chemical washing and sintering in an oven. The chemical washing often involves immersing the parts in a chamber with vaporized nitric acid. The parts are then heated to remove the plastic parts. Only the metal dust remains. The parts are then placed in an oven. They are subjected to even higher temperatures. However, this is done with care to avoid melting them. The heating helps to fuse the metal powder particles together. The parts may therefore shrink in size.
Post-processing is often done in a separate facility as it requires specialized equipment.
Applications of 3D Printing with Metal
Are you looking for 3D printer ideas for metal 3D printing? 3D printing with metal is finding many applications. You can print just about any metal part. Some common examples of metal parts made using 3D printing include orthopedic implants, printer nozzles, hooks, auto parts, and many more. If you're considering getting into metal 3D printing, you may want to consider the different technologies available for 3D metal printing. You may also want to try metal 3D printing at home with metal filament. However, post-processing may prove to be challenging if you are unable to identify a facility that offers these services. This is something that continues to make 3D metal printing prohibitive, especially for hobbyists.