When you think of 3D printing, you probably don’t think about metal. However, metal 3D printing is now a very important part of the additive manufacturing industry. In this article, we will explore some of the nuances involved in metal 3D printing and why it is so important for the future of additive manufacturing. We have discussed in detail about plastic 3D printers in our blog earlier as well. But today, the prominence of metal 3D printing cannot be ignored any longer. They are becoming more popular by the day and here’s why…

Understanding the Basics of Metal 3D Printing

Before diving into the nuances and complexities of metal 3D printing, let’s first understand the basics of 3D printing with metal. The process is similar to plastic 3D printing in that a digital model is first designed on a computer. Then, the model is broken down into layers, and a machine builds the design layer by layer using a metal material. There are many methods to 3D print with metal and they vary in complexity, type of metal used, and the design process. Let’s take a look at some of the most common metal 3D printing methods. - Electron Beam Melting (EBM) - EBM is a method of additive manufacturing. In EBM, a computer-driven source emits high-energy electrons that excite metal powder. The metal is melted by the electron beam and then solidified by the reaction between it and the metal powder. - Directed Energy Deposition (DED) - DED is a type of metal 3D printing that uses a laser to melt metal powder. The laser heats the powder and then deposits it onto a build platform. - Laser-Sintered Metal (Laser SM) - Laser-Sintered Metal 3D printing involves a laser that fuses metal powder together. This method requires a controlled atmosphere to reduce the amount of carbon in the metal. - Electron Beam Additive Manufacturing (EBAM) - EBAM is similar to EBM, but it uses a powerful electron beam to melt metal powder.

Why Is Metal 3D Printing Important?

Metal 3D printing applications are growing in number and are becoming increasingly important due to the wide range of industries they can be used in. Industries like aerospace, automotive, shipbuilding, and medical are now adopting the use of metal 3D printing for production because of the advantages it offers over traditional manufacturing. - Metal 3D printing offers a lot of advantages over other manufacturing methods, such as laser cutting, CNC machining, and casting. With casting, you have to make molds, which is expensive and time-consuming. With laser cutting, you can only make simple shapes, so it is not ideal for complex designs. With CNC machining, you can create complex shapes, but it is time-consuming and expensive. Metal 3D printing is an alternative to traditional manufacturing methods since it combines the benefits of all three methods. It can create complex shapes that are difficult to create with CNC machining, and it is more affordable than casting. - This is important because it means that companies won’t have to rely on traditional manufacturing methods to create their products. With 3D printing, they can create whatever they want and have a new way of doing business.

The Many Types of Metal 3D Printing

Now that we have discussed the basics of metal 3D printing, let’s look at the many different types of 3D printing that involve metal. These different methods may have different names, but they don’t differ too much from each other. - Electron Beam Melting (EBM) - EBM, Electron Beam Additive Manufacturing (EBAM), and EBM-S involve the same basic process: a computer-driven source emits high-energy electrons that excite metal powder. The metal is melted by the electron beam and then solidified by the reaction between it and the metal powder. - Directed Energy Deposition (DED) - DED is a type of metal 3D printing that is similar to Laser-Sintered Metal (Laser SM). In Laser SM, a laser heats up metal powder and then deposits it onto a build platform. In DED, a laser heats up metal powder and then deposits it onto a build platform. - Laser-Sintered Metal (Laser SM) - Laser-Sintered Metal 3D printing involves a laser that fuses metal powder together. This method requires a controlled atmosphere to reduce the amount of carbon in the metal. - Electron Beam Additive Manufacturing (EBAM) - EBAM is similar to EBM, but it uses a powerful electron beam to melt metal powder.

Limitations of Metal 3D Printing

As amazing as metal 3D printing is, there are a few limitations that you should be aware of. One common issue is that the parts created through metal 3D printing have a porous finish. This is because the 3D printing process leaves some of the metal powder unmelted, which leaves pores in the part. - Another drawback of metal 3D printing is that it is not suitable for every type of metal. Since the process relies on a laser to fuse metal powder together, it is important that the metal is able to withstand high temperatures. This means that some types of metal are not suitable for the process.

Key takeaways

While the future of plastic 3D printing is unclear, it is clear that the future of metal 3D printing is bright. This is because metal 3D printing offers advantages over plastic 3D printing. This means that businesses that are currently using plastic 3D printing to produce their products will soon have access to metal 3D printing. There are many types of metal 3D printing and they are used in industries like aerospace, automotive, shipbuilding, and medical. There are a few limitations of metal 3D printing, but the advantages of this process are clear.