Metal 3D printing

Metal 3D printing encompasses various additive manufacturing processes in which metallic starting materials (powder or wire) are processed in layers. The aim is to produce resilient metal components that would otherwise often have to be milled or cast in a conventional, often costly and time-consuming manner.

Process
In practice, several technologies are used. Often, a fine metal powder is selectively melted using laser or electron beams (e.g. selective laser melting, SLM). Other methods use binders to initially form the powder before a sintering step in the furnace produces the final strength.

Typical materials

• steel (e.g. tool steel)
• aluminium alloys
• titanium and other heat-resistant metals.

Areas of application

• Tool and mould making: production of complex injection and die casting moulds with conformal cooling channels.
• Aviation: high-strength lightweight components.
• Medical technology: customised implants, prostheses and instruments.

Advantages and disadvantages

• Advantages: high component stability and resilience, freedom of geometry, savings on tool costs.
• Disadvantages: metal powder and equipment are cost-intensive, the construction space is often limited. The process control requires specialised knowledge.