{"id":11894,"date":"2022-06-14T15:08:46","date_gmt":"2022-06-14T08:08:46","guid":{"rendered":"https:\/\/aie.com.vn\/?p=11894"},"modified":"2023-05-13T11:16:49","modified_gmt":"2023-05-13T04:16:49","slug":"introduction-to-common-metal-3d-printing-materials","status":"publish","type":"post","link":"https:\/\/aie.com.vn\/en\/introduction-to-common-metal-3d-printing-materials\/","title":{"rendered":"Introduction to common metal 3D printing materials"},"content":{"rendered":"<p style=\"text-align: justify;\">Metal <a href=\"https:\/\/en.wikipedia.org\/wiki\/3D_printing\" target=\"_blank\" rel=\"noopener\"><span style=\"text-decoration: underline;\"><em><span style=\"color: #0000ff; text-decoration: underline;\">additive manufacturing<\/span><\/em><\/span><\/a>\u00a0processes boast considerable advantages over traditional methods like CNC machining or injection molding.<\/p>\n<p style=\"text-align: justify;\">One of those advantages is material waste reduction, which can be critical when using expensive metals like copper or precious metals. Indeed, metal 3D printing uses only the amount of material necessary to create a part, with just a\u00a0<strong>minimal amount of waste<\/strong>\u00a0generated by the support structures.<\/p>\n<p style=\"text-align: justify;\">Furthermore, since 3D printing unlocks complex geometrical design possibilities, it\u2019s possible to\u00a0<strong>optimize part topology, density, and weight<\/strong>, which helps save even more on metal 3D printing materials.<\/p>\n<p style=\"text-align: justify;\">Let\u2019s take a look at some of the most commonly used metal 3D printing materials on the market.<\/p>\n<div class=\"wp-block-image\" style=\"text-align: center;\">\n<figure class=\"aligncenter size-large\"><img decoding=\"async\" class=\"aligncenter\" src=\"https:\/\/www.aie.com.vn\/wp-content\/uploads\/2022\/06\/11894.jpg\" alt=\"metal 3D printing materials\" width=\"636\" height=\"446\" \/><figcaption><span style=\"font-size: 10pt;\"><strong><em>Selective laser melting metal 3D printing by DMG MORI. Source: 3dprintingmedia.network<\/em><\/strong><\/span><\/figcaption><\/figure>\n<\/div>\n<div class=\"wp-block-group\" style=\"text-align: justify;\">\n<div class=\"wp-block-group__inner-container\">\n<h2 id=\"maraging-steel-tool-steel\" class=\"\" data-niveau-lien=\"1\">Maraging steel (Tool steel)<\/h2>\n<p>Maraging steel can be quite expensive, mostly due to its\u00a0<strong>high levels of alloying<\/strong>\u00a0(~0.03% carbon, ~17 to 19% nickel, and ~8 to 12% cobalt) necessary to provide a combination of both high tensile strength and high fracture toughness.<\/p>\n<p>Quality often comes at a price, and although it is rather expensive, maraging steel is a material that offers\u00a0<strong>one of the best strength-to-weight ratios on the market<\/strong>\u00a0and high damage tolerance. Maraging steel has outstanding mechanical properties and can be heat-treated easily to deliver superior hardness and durability.<\/p>\n<p>This makes the material ideal for a wide range of tooling applications such as injection molding tools, cores, and inserts of die casting, punch pressing, as well as for heavy-duty engineered parts, such as in automotive and aerospace applications.<\/p>\n<ul>\n<li><strong>Commonly used alloys:\u00a0<\/strong>MS1, 18Ni1400, 18Ni1700, 18Ni1900, 18Ni2400, 17Ni1600 (cast)<\/li>\n<li><strong>Material format(s):<\/strong>\u00a0Powder, filament<\/li>\n<li><strong>3D printing technology:\u00a0<\/strong>Direct Metal Laser Sintering (DMLS), Fused Filament Fabrication (FFF)<\/li>\n<\/ul>\n<div class=\"wp-block-image\" style=\"text-align: center;\">\n<figure class=\"aligncenter size-large\"><img decoding=\"async\" class=\"aligncenter\" src=\"https:\/\/www.aie.com.vn\/wp-content\/uploads\/2022\/06\/11894-1.jpg\" alt=\"\" width=\"759\" height=\"569\" \/><figcaption><em><strong><span style=\"font-size: 10pt;\">Watch structures 3D printed using maraging steel. Source:\u00a0Rapidsol<\/span><\/strong><\/em><\/figcaption><\/figure>\n<\/div>\n<\/div>\n<\/div>\n<div class=\"wp-block-group\" style=\"text-align: justify;\">\n<div class=\"wp-block-group__inner-container\">\n<h2 id=\"stainless-steel\" class=\"\" data-niveau-lien=\"2\">Stainless steel<\/h2>\n<p>Stainless steel is known to be a\u00a0<strong>less expensive alternative to titanium or nickel<\/strong>, while still having very valuable characteristics.<\/p>\n<p>Due to its superior hardness and toughness, excellent corrosion resistance, good weldability, and highly ductile properties, stainless steel has become popular in the aerospace, oil and gas, food services, and health care industries.<\/p>\n<ul>\n<li><strong>Commonly used alloys:<\/strong>\u00a017-4PH and 316L alloys<\/li>\n<li><strong>Material format(s):<\/strong>\u00a0Powder, filament<\/li>\n<li><strong>3D printing technology:<\/strong>\u00a0Direct Metal Deposition (DMD), Binder Jetting, Direct Metal Laser Sintering (DMLS), and Stratoconception<\/li>\n<\/ul>\n<div class=\"wp-block-image\" style=\"text-align: center;\">\n<figure class=\"aligncenter size-large\"><img decoding=\"async\" class=\"aligncenter\" src=\"https:\/\/www.aie.com.vn\/wp-content\/uploads\/2022\/06\/11894-2.jpg\" alt=\"\" \/><figcaption><em><strong><span style=\"font-size: 10pt;\">Printed stainless steel lattice structure. Source:\u00a0azom.com<\/span><\/strong><\/em><\/figcaption><\/figure>\n<\/div>\n<\/div>\n<\/div>\n<div class=\"wp-block-group\" style=\"text-align: justify;\">\n<div class=\"wp-block-group__inner-container\">\n<h2 id=\"titanium\" class=\"\" data-niveau-lien=\"3\">Titanium<\/h2>\n<p>With its superior biocompatibility, great strength and durability, high corrosion resistance, and good density, titanium is an\u00a0<strong>interesting material for harsh environment applications<\/strong>\u00a0related to the automotive, aviation, and medical\/dental sectors.<\/p>\n<p>A perfect example of industrial 3D printed titanium is Bugatti. In 2018, a dedicated brake caliper brake caliper pattern has been optimized with a more organic shape. The\u00a0<strong>45-hour print<\/strong>\u00a0succeeded in making the part\u00a0<strong>40% lighter and capable of enduring up to 125 kg per square millimeter<\/strong>.<\/p>\n<ul>\n<li><strong>Commonly used alloys:\u00a0<\/strong>Ti6Al4V or Ti64<\/li>\n<li><strong>Material format(s):\u00a0<\/strong>Powder, filament<\/li>\n<li><strong>3D Printing technology:<\/strong>\u00a0Direct Energy Deposition (DED), Electron Beam Melting (EBM), Fused Filament Fabrication (FFF)<\/li>\n<\/ul>\n<div class=\"wp-block-image\" style=\"text-align: center;\">\n<figure class=\"aligncenter size-large\"><img decoding=\"async\" class=\"aligncenter\" src=\"https:\/\/www.aie.com.vn\/wp-content\/uploads\/2022\/06\/11894-3.jpg\" alt=\"metal 3D printing materials\" width=\"649\" height=\"433\" \/><figcaption><span style=\"font-size: 10pt;\"><strong><em>Brake Caliper 3D printed in Titanium for Bugatti. Source: Bugatti<\/em><\/strong><\/span><\/figcaption><\/figure>\n<\/div>\n<\/div>\n<\/div>\n<div class=\"wp-block-group\" style=\"text-align: justify;\">\n<div class=\"wp-block-group__inner-container\">\n<h2 id=\"aluminum\" class=\"\" data-niveau-lien=\"4\">Aluminum<\/h2>\n<p>Aluminum is a material of choice for the automotive and aerospace industries. It is primarily used to produce lightweight, geometrically complex parts that meet the standards of these demanding industries.<\/p>\n<p>Aluminum has good chemical resistance, great corrosion resistance, and, most importantly, has\u00a0<strong>one of the best strength-to-weight ratios<\/strong>\u00a0of any metal. Its\u00a0post-processing\u00a0convenience, ability to withstand high temperatures, and thermal and electrical conductivity are also very important characteristics for heavy industries.<\/p>\n<ul>\n<li><strong>Commonly used alloys:<\/strong>\u00a0AlSi10Mg, AlSi12, AlSi12Mg alloys, Scalmalloy, ALSi7Mg, AlSi7Mg0, Al 6061 and Al 7075, AU4G1<\/li>\n<li><strong>Material format(s):<\/strong>\u00a0Powder, filament<\/li>\n<li><strong>3D printing technology:<\/strong>\u00a0Laser powder bed fusion (LPBF), electron beam powder bed fusion, binder jetting, and more rarely fused deposition modeling (FDM)<\/li>\n<\/ul>\n<div class=\"wp-block-image\" style=\"text-align: center;\">\n<figure class=\"aligncenter size-large\"><img decoding=\"async\" class=\"\" src=\"https:\/\/www.aie.com.vn\/wp-content\/uploads\/2022\/06\/11894-4.jpg\" alt=\"\" width=\"799\" height=\"418\" \/><figcaption><em><strong><span style=\"font-size: 10pt;\">Ford and ExOne binder jet 3D printing and sintering process for Aluminum. Source:\u00a0ExOne<\/span><\/strong><\/em><\/figcaption><\/figure>\n<\/div>\n<\/div>\n<\/div>\n<div class=\"wp-block-group\" style=\"text-align: justify;\">\n<div class=\"wp-block-group__inner-container\">\n<h2 id=\"cobalt-chromium-alloy\" class=\"\" data-niveau-lien=\"5\">Cobalt chromium alloy<\/h2>\n<p>Although it is sometimes used to produce engine components, the main domain of use of this material is in medical applications such as\u00a0surgical and dental implants.<\/p>\n<p>Indeed, it is fully biocompatible, has high strength, high resistance to corrosion as well as temperature resistance, and is non-magnetic. This makes it a\u00a0<strong>perfect material for medical usage<\/strong>.<\/p>\n<ul>\n<li><strong>Commonly used alloys:\u00a0<\/strong>CoCrMo<\/li>\n<li><strong>Material format(s):\u00a0<\/strong>Powder<\/li>\n<li><strong>3D printing technology:<\/strong>\u00a0Direct Metal Laser Sintering (DMLS)<\/li>\n<\/ul>\n<div class=\"wp-block-image\" style=\"text-align: center;\">\n<figure class=\"aligncenter size-large\"><img decoding=\"async\" class=\"aligncenter\" src=\"https:\/\/www.aie.com.vn\/wp-content\/uploads\/2022\/06\/11894-5.jpg\" alt=\"metal 3D printing materials\" width=\"679\" height=\"476\" \/><figcaption><span style=\"font-size: 10pt;\"><strong><em>Additive Manufacturing Process for the dental industry. Source:\u00a0EOS<\/em><\/strong><\/span><\/figcaption><\/figure>\n<\/div>\n<\/div>\n<\/div>\n<div class=\"wp-block-group\" style=\"text-align: justify;\">\n<div class=\"wp-block-group__inner-container\">\n<h2 id=\"nickel-alloys\" class=\"\" data-niveau-lien=\"6\">Nickel alloys<\/h2>\n<p>Nickel is an\u00a0<strong>incredibly versatile material<\/strong>\u00a0capable of alloying with many other metals. Ideal for demanding 3D printing applications, nickel alloys find use in a wide range of demanding industries such as aerospace, chemical processing, and shipbuilding.<\/p>\n<p>Due to their high durability at elevated temperatures and\u00a0<strong>extensive corrosion resistance<\/strong>\u00a0in extreme environments, they can be used, for example, in gas turbine blades for jet engines, turbine power plants, and in highly critical nuclear power systems.<\/p>\n<p>In addition, parts made of nickel alloys have good tensile strength and fracture resistance.<\/p>\n<ul>\n<li><strong>Commonly used alloys:<\/strong>\u00a0Inconel 625, Inconel 713, Inconel 718, Inconel 738, Inconel 939, Hastelloy X, Haynes 282, Amperprint alloy 625 and 718<\/li>\n<li><strong>Material format(s):\u00a0<\/strong>Powder, filament<\/li>\n<li><strong>3D printing technology:\u00a0<\/strong>Direct Metal Laser Sintering (DMLS), Fused Filament Fabrication (FFF)<\/li>\n<\/ul>\n<div class=\"wp-block-image\" style=\"text-align: center;\">\n<figure class=\"aligncenter size-large\"><img decoding=\"async\" class=\"aligncenter\" src=\"https:\/\/www.aie.com.vn\/wp-content\/uploads\/2022\/06\/11894-6.jpg\" alt=\"\" width=\"524\" height=\"349\" \/><figcaption><span style=\"font-size: 10pt;\"><strong><em>Nitinol, a titanium and nickel alloy used for its shape-memory capabilities and 3D printed using a powder bed fusion process.<br \/>\nSource:\u00a0CSIRO Research<\/em><\/strong><\/span><\/figcaption><\/figure>\n<\/div>\n<\/div>\n<\/div>\n<div class=\"wp-block-group\" style=\"text-align: justify;\">\n<div class=\"wp-block-group__inner-container\">\n<h2 id=\"copper-based-alloys\" class=\"\" data-niveau-lien=\"7\">Copper-based alloys<\/h2>\n<p>3D printing copper with traditional metal powder-based 3D printing technologies, such as direct metal laser sintering (DMLS), has been a\u00a0<strong>long-standing challenge<\/strong>\u00a0due to copper\u2019s high thermal conductivity.<\/p>\n<p>The most common process for 3D printing copper is powder bed fusion. But new processing methods, such as\u00a0Markforged Metal X fused filament fabrication (FFF), are helping to improve the use of copper for additive manufacturing.<\/p>\n<p>Thanks to their\u00a0<strong>excellent thermal and electrical conductivity<\/strong>, coupled with good mechanical properties and high malleability, copper-based alloys are ideal for tooling, thermal management applications, and electrical engineering, such as the fabrication of inductors, electrodes, or even heat exchangers.<\/p>\n<ul>\n<li><strong>Commonly used alloys:\u00a0<\/strong>CuNi2SiCr, CuCrZr, CuCP, Cu<\/li>\n<li><strong>Material format(s):<\/strong>\u00a0Powder, filament<\/li>\n<li><strong>3D printing technology:<\/strong>\u00a0Direct Metal Laser Sintering (DMLS), Fused Filament Fabrication (FFF)<\/li>\n<\/ul>\n<div class=\"wp-block-image\" style=\"text-align: center;\">\n<figure class=\"aligncenter size-large\"><img decoding=\"async\" class=\"aligncenter\" src=\"https:\/\/www.aie.com.vn\/wp-content\/uploads\/2022\/06\/11894-7.jpg\" alt=\"\" width=\"673\" height=\"449\" \/><figcaption><em><strong><span style=\"font-size: 10pt;\">Copper 3D printing using Beamler 3d printing services. Source:\u00a0Beamler<\/span><\/strong><\/em><\/figcaption><\/figure>\n<\/div>\n<\/div>\n<\/div>\n<div class=\"wp-block-group\" style=\"text-align: justify;\">\n<div class=\"wp-block-group__inner-container\">\n<h2 id=\"precious-metals\" class=\"\" data-niveau-lien=\"8\">Precious metals<\/h2>\n<p>3D printing of precious metals is ideal for industries such as jewelry, watches, dentistry (crowns, inlays, and onlays), and electronics because of the\u00a0<strong>high levels of design freedom<\/strong>\u00a0it offers.<\/p>\n<p>But direct manufacturing of these precious metals can be challenging. Indeed, most precious metals (gold and silver for example) are\u00a0<strong>highly reflective and thermally conductive<\/strong>. Traditional AM laser-based printers are unable to completely melt the materials and create a homogeneous part. Only a few manufacturers have developed 3D printers performant enough to process these precious metal materials using Direct Metal Laser Sintering (DMLS) or Material Jetting.<\/p>\n<p>It is also important to note that precious metal powders can be\u00a0<strong>very costly<\/strong>. For this reason, most precious metal 3D printing applications involve indirect manufacturing, with a wax model to be used for investment casting.<\/p>\n<ul>\n<li><strong>Commonly used metals:<\/strong>\u00a0Gold, Silver, Platinum<\/li>\n<li><strong>Material format(s):<\/strong>\u00a0Powder<\/li>\n<li><strong>3D printing technology:<\/strong>\u00a0Direct Metal Laser Sintering (DMLS) and Material Jetting<\/li>\n<\/ul>\n<div class=\"wp-block-image\" style=\"text-align: center;\">\n<figure class=\"aligncenter size-large\"><img decoding=\"async\" class=\"aligncenter\" src=\"https:\/\/www.aie.com.vn\/wp-content\/uploads\/2022\/06\/11894-8.jpg\" alt=\"metal 3D printing materials\" width=\"612\" height=\"372\" \/><figcaption><span style=\"font-size: 10pt;\"><strong><em>Custom jewelry earrings 3D printed using gold powder material. Source: 3Dprint.com<\/em><\/strong><\/span><\/figcaption><\/figure>\n<\/div>\n<\/div>\n<\/div>\n<div class=\"wp-block-group\" style=\"text-align: justify;\">\n<div class=\"wp-block-group__inner-container\">\n<h2 id=\"refractory-metals\" class=\"active\" data-niveau-lien=\"9\">Refractory metals<\/h2>\n<p>Refractory metals are extremely resistant materials with an\u00a0<strong>incredibly high melting point<\/strong>. This same high melting point combined with their low thermal expansion, high strength, and hardness make them suitable for high-tech applications and power electronics. They also feature a high thermal and electrical conductivity mixed with high wear resistance.<\/p>\n<p>While\u00a0<strong>tantalum and niobium are mainly used in the medical industry<\/strong>\u00a0for their biocompatibility, good oxidation, and chemical stability,\u00a0<strong>tungsten and molybdenum are preferred for applications such as aerospace, automotive and nuclear applications<\/strong>\u00a0due to their high density and radiation screening capabilities.<\/p>\n<p>Due to the high density of some of these materials (such as Tungsten), it is necessary to use\u00a0<strong>less common 3D printing technologies<\/strong>, such as electron beam melting (EBM) or even selective deposition of a liquid agent to bind the powder, instead of traditional laser-based printers.<\/p>\n<ul>\n<li><strong>Commonly used metals:<\/strong>\u00a0Tantalum, Niobium, Molybdenum, Rhenium, and Tungsten<\/li>\n<li><strong>Material format(s):\u00a0<\/strong>Powder<\/li>\n<li><strong>3D printing technology:\u00a0<\/strong>Electron-beam melting (EBM), Laser Beam Melting (LBM), Binder Jetting<\/li>\n<\/ul>\n<div class=\"wp-block-image\" style=\"text-align: center;\">\n<figure class=\"aligncenter size-large\"><img decoding=\"async\" class=\"aligncenter\" src=\"https:\/\/www.aie.com.vn\/wp-content\/uploads\/2022\/06\/11894-9.jpg\" alt=\"\" \/><figcaption><span style=\"font-size: 10pt;\"><em><strong>Tungsten 3D printing using an LBM (Laser Beam Melting) process. Source:\u00a0Institute of Rare Earths and Strategic Metals<\/strong><\/em><\/span><\/figcaption><\/figure>\n<\/div>\n<\/div>\n<\/div>\n<h2 id=\"conclusion\" class=\"\" style=\"text-align: justify;\" data-niveau-lien=\"10\">Conclusion<\/h2>\n<p style=\"text-align: justify;\">We can see that over the years, metal 3D printing technologies and processes have been expanding thanks to the efforts of many manufacturers around the world.<\/p>\n<p style=\"text-align: justify;\">Thus, new materials are becoming available to meet the specific needs of more and more industries. From automotive and aerospace to nuclear safety and medical industries, metal additive manufacturing is providing innovative solutions where traditional subtractive manufacturing finds its limits.<\/p>\n<hr \/>\n<p><em><span style=\"text-decoration: underline;\"><a href=\"https:\/\/aie.com.vn\/en\/contact\/\"><span style=\"color: #0000ff; text-decoration: underline;\">Contact us<\/span> <\/a><\/span><\/em>if you have any questions!<\/p>\n","protected":false},"excerpt":{"rendered":"<p>Metal additive manufacturing\u00a0processes boast considerable advantages over traditional methods like CNC machining or injection molding. One of those advantages is material waste reduction, which can be critical when using expensive metals like copper or precious metals. Indeed, metal 3D printing uses only the amount of material necessary to create a part, with just a\u00a0minimal amount&#8230;<\/p>\n","protected":false},"author":10,"featured_media":11846,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"footnotes":""},"categories":[52,35],"tags":[],"class_list":["post-11894","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-blog-en","category-news"],"_links":{"self":[{"href":"https:\/\/aie.com.vn\/en\/wp-json\/wp\/v2\/posts\/11894","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/aie.com.vn\/en\/wp-json\/wp\/v2\/posts"}],"about":[{"href":"https:\/\/aie.com.vn\/en\/wp-json\/wp\/v2\/types\/post"}],"author":[{"embeddable":true,"href":"https:\/\/aie.com.vn\/en\/wp-json\/wp\/v2\/users\/10"}],"replies":[{"embeddable":true,"href":"https:\/\/aie.com.vn\/en\/wp-json\/wp\/v2\/comments?post=11894"}],"version-history":[{"count":0,"href":"https:\/\/aie.com.vn\/en\/wp-json\/wp\/v2\/posts\/11894\/revisions"}],"wp:featuredmedia":[{"embeddable":true,"href":"https:\/\/aie.com.vn\/en\/wp-json\/wp\/v2\/media\/11846"}],"wp:attachment":[{"href":"https:\/\/aie.com.vn\/en\/wp-json\/wp\/v2\/media?parent=11894"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/aie.com.vn\/en\/wp-json\/wp\/v2\/categories?post=11894"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/aie.com.vn\/en\/wp-json\/wp\/v2\/tags?post=11894"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}