1. What is Metal 3D Printing Technology? 

Additive manufacturing, also known as 3D printing, is a process that joins materials layer by layer to create objects, contrasting with traditional CNC subtractive methods. 

Metal 3D printing, or Selective Laser Melting (SLM), is an advanced manufacturing technology that combines the design flexibility of 3D printing with the superior mechanical properties of metal materials. This technology uses high-intensity laser beams to melt and fuse layers of metal powder, creating unique, strong, and durable components. 

SLM is the most popular metal 3D printing technology 

Metal 3D printing is not only ideal for creating perfect prototypes but also finds practical applications in various complex fields such as aerospace, medical, automotive, and energy engineering. This technology accelerates the production process, saves time and costs, and minimizes material waste, producing engineering products with high durability, excellent heat resistance, and complex designs that surpass the capabilities of traditional methods. 

1.1. Working Principle of Metal 3D Printing 

A thin layer of metal powder is spread on the print bed, and a high-power laser beam scans across, melting (or binding) the metal particles together to form the next layer. After the laser scan, the recoater system spreads another thin layer of metal powder, repeating this process until the entire part is completed. 

Laser metal melting process of SLM 280 machine 

1.2. Metal 3D Printing Process 

🔸3D Design and Simulation Calculation 

• 3D Design: Users need to create a detailed 3D model of the desired product using specialized CAD (Computer-Aided Design) software such as SolidWorks, Autodesk Inventor, or CATIA. Additionally, 3D scanning technology can be used to collect data on the shape, appearance, and color of the object, which is then converted into a highly accurate digital model. 

• Simulation Calculation: Simulation software is used to predict factors such as stress, deformation, warping, and temperature during the printing process, helping to optimize the design to ensure accuracy and minimize printing errors. Depending on the requirements and usage, engineers can choose design and simulation software like Materialise, Simufact, Ansys, nTop, or Siemens.  

Design and calculation of Vinnotek's heat sink simulation 

🔸Material Selection 

This crucial step involves selecting suitable materials to create high-strength products tailored for specific industries. Common materials include stainless steel, superalloys, titanium, copper, and aluminum. 

🔸Printer Preparation 

Check the operation of key components such as the laser system, cooling system, print chamber, material feed system, pneumatic system, and inert gas system to ensure accurate calibration. Then, set up printing parameters suitable for the material, size, and complexity of the part. 

🔸Metal 3D Printing 

Provide the design data to the printer and monitor the printing process to detect and promptly address issues such as porosity, peeling, deformation, or dimensional deviations. To minimize problems, carefully prepare and inspect the printer before printing and perform simulation calculations for the printed part. 

🔸Post-Processing 

After completing the metal 3D printing process, post-processing is crucial for finishing the product, enhancing precision, and treating the surface to remove residual metal powder and polish if needed. Remove support structures printed with the part using manual, specialized tools, or chemical methods. 

2. Metal 3D Printing Methods 

2.1. Powder Bed Fusion (PBF) 

Powder Bed Fusion is a common additive manufacturing technology where heat from an energy source such as a laser or electron beam is used to melt or fuse materials (in powder form) layer by layer, creating a complete 3D object. 

In metal 3D printing, the process involves spreading a layer of powder material on the print bed, and then selectively scanning the energy source to melt or bind the powder according to the 3D CAD data. The print bed then lowers by the desired layer thickness, a roller spreads another layer of powder, and the energy source again selectively scans the new powder layer. This process repeats until the entire object is built; finally, the printed part is extracted from the powder bed and cleaned or further processed. 

Standard PBF technologies include Direct Metal Laser Sintering (DMLS), Selective Laser Melting (SLM), and Electron Beam Melting (EBM): 

Selective Laser Melting (SLM) 

SLM, also known as Selective Laser Melting, is one of the most commonly used and advanced metal 3D printing technologies today. This process is very similar to SLS but uses much higher beam energy. SLM employs a high-energy laser to selectively melt metal powder particles layer by layer, forming complex and precise 3D products. 

Directed Energy Deposition (DED) 

DED is defined as a process where concentrated thermal energy is used to melt materials in the form of metal powder or wire as they are deposited. This technology involves a nozzle mounted on a multi-axis arm, sometimes combined with CNC milling. The nozzle can move around a fixed object in multiple directions to deposit material on the desired surfaces according to the CAD model geometry, with a high-energy beam melting the material which solidifies immediately on the substrate.  
 

Electron Beam Melting (EBM) 

EBM is an additive manufacturing method similar to SLM, with the main difference being that EBM uses an electron beam to melt metal powder in a high vacuum environment. In this process, high-speed electrons hit the powder layer and convert kinetic energy into thermal energy (source), achieving higher production speeds compared to laser melting methods.  
 

EBM technical diagram (Bansal et al., 2023)

2.2. Metal Binder Jetting (MBJ) 

Metal Binder Jetting (MBJ) is an additive manufacturing process where metal powder is spread in a primary direction to form a layer, and binder droplets are deposited on the powder layer to combine with the powder material. The print bed then lowers and another layer of powder is spread. This technology uses a printhead to jet a binder onto the metal powder, forming a 3D product with high production speed for complex parts without significant heating during printing. 

Besides metals, the binder jetting method can be applied to various materials, such as sand and ceramics. 

You can learn more about metal 3D printing here: COMPARISON OF 3D METAL PRINTING TECHNOLOGIES: SLM, EBM, AND BINDER JETTING

3. Advantages and Disadvantages of using Metal 3D printing 

3.1. Advantages 

• Design flexibility: Metal 3D printing creates complex products, eliminating the limitations of mold shapes, allowing for the creation of intricate, small-sized, and detailed products unattainable with traditional methods. 

• Product personalization: It enables personalized products tailored to user requirements and preferences, creating custom products with a personal touch. 

• Product optimization: Metal 3D printing optimizes design, maximizes material use, and reduces product weight, enhancing operational efficiency. The resulting products have high durability and precision, extending lifespan and performance. 

• Shortened production time: This technology can create products faster than traditional methods, saving time and costs, and reducing the time to market. 

• Reduced production costs: It lowers machining costs, reduces waste, and cuts transportation costs compared to traditional methods. Metal 3D printing uses only the material necessary for the product, minimizing waste and protecting the environment. 

• Wide application potential: With the ability to create complex, custom parts with superior durability, metal 3D printing is used in various fields such as aerospace, medical, machinery manufacturing, automotive, energy, and construction. 

Watch more: DUAL BENEFITS FOR ECONOMY AND ENVIRONMENT OF METAL 3D PRINTING TECHNOLOGY

3.2. Challenges 

• High technical requirements: Operating the printer requires specialized skills and knowledge of metal 3D printing technology and metalworking. 

• Slow printing speed: Compared to plastic 3D printing technologies, metal printing speed is usually slower due to the process involving multiple steps like material melting and layer-by-layer deposition. 

• High investment costs: The investment cost for metal 3D printers and materials is higher than for plastic 3D printers, requiring substantial capital investment. 

• Surface quality: The surface of metal 3D printed products may not be smooth and may require additional processing to achieve the desired finish. 

• Prone to errors: Metal 3D printing can achieve high precision but can still be prone to errors due to factors like machine settings, printing materials, and the surrounding environment. 

Despite some challenges, metal 3D printing continues to develop and breakthrough, unlocking immense potential for multi-industry production. 

Learn more: TOP 6 THINGS YOU NEED TO KNOW ABOUT 3D METAL PRINTING

4. Materials used in Metal 3D Printing technology 

Metal 3D printing materials play a crucial role in creating products with high durability, excellent corrosion resistance, and suitability for various industrial applications. Common materials include stainless steel, superalloys, titanium, copper, and aluminum, each with unique properties and applications. 

4.1. Stainless Steel and Tool Steel 

Stainless steel and tool steel are among the most widely used materials in metal 3D printing. 

4.1.1. Stainless Steel 

• Martensitic Stainless Steel: Hard but brittle, with less corrosion resistance. A common example is 17-4 PH, which can be heat-treated for various applications. 

• Austenitic Stainless Steel: High ductility and better corrosion resistance, often used in corrosive environments. 

 
Stainless steel is one of the most popular materials in metal 3D printing

4.1.2. Tool Steel 

• A-Series Tool Steel: Balances wear resistance and toughness, commonly used for punches and dies. 

• D-Series Tool Steel: Optimized for wear resistance, with D2 being widely used for cutting tools. 

• H-Series Tool Steel: Used at high temperatures, with H13 being optimized for hot working and cutting applications. 

4.2. Superalloys 

Superalloys are designed to operate in extreme conditions, such as high temperatures and corrosive environments. They offer exceptional strength and corrosion resistance, making them ideal for applications requiring high mechanical strength and thermal stability. 

Inconel: 

• Characteristics: A group of nickel-chromium-based superalloys known for high corrosion and heat resistance. 

• Applications: Used in jet engines, exhaust systems, and gas turbines. Inconel 718 is particularly popular in aerospace and energy production for its ability to withstand temperatures up to 700°C while maintaining high mechanical strength. 

• Characteristics: A cobalt-based superalloy with excellent corrosion and wear resistance, as well as high biocompatibility. 

• Applications: Widely used in the medical field for implants such as dental prosthetics, hip joints, and other orthopedic devices. Its biocompatibility minimizes allergic reactions and promotes natural bone growth when implanted. 

3D printing gas tubin with super alloy 

4.3. Titanium 

Titanium is a metal known for its high strength-to-weight ratio, corrosion resistance, and heat tolerance. It is widely used in various industries due to its durability and light weight. 

Aerospace Applications: 

• Aircraft and Engine Parts: Titanium is used to manufacture critical aircraft and engine components such as blades, exhausts, and engine casings. Titanium alloys (e.g., Ti-6Al-4V) are commonly used for structural parts and high-temperature components in aircraft. 

Medical Applications: 

• Implants: Titanium is used to make implants such as knee joints, hip joints, and bone screws due to its high biocompatibility, light weight, and strength. It does not react with the human body, ensuring long-lasting implants without complications. 

3D printing metal crown with titanium material 

4.4. Copper 

Copper is a metal known for its excellent thermal and electrical conductivity, making it ideal for electrical engineering and thermal management applications. 

Electronics Applications: 

• Inductors, Electrodes, Heat Exchangers: Copper is extensively used in the production of electronic devices such as inductors, electrodes, and heat exchangers due to its high electrical and thermal conductivity. Copper is also used in printed circuit boards and other electronic components. 

Common Alloys: 

• CuNi2SiCr, CuCrZr, CuCP: These alloys enhance the mechanical properties of copper, improving strength and wear resistance. CuNi2SiCr is used in high-temperature applications, CuCrZr in welding electrodes, and CuCP in high electrical conductivity applications. 

4.5. Aluminum 

Aluminum and aluminum alloys are lightweight materials with high strength and ease of processing, widely used in many industries due to their excellent mechanical properties and good corrosion resistance. 

Popular Alloy: 

• AlSi10Mg: One of the most popular aluminum alloys used in 3D printing, AlSi10Mg offers excellent mechanical properties, particularly high strength and hardness, along with good thermal resistance, making it suitable for industrial applications requiring high precision and durability. 

Applications: 

• Automotive, Aerospace, and Lightweight mechanical parts: Aluminum is used to manufacture parts for automobiles, aircraft, and mechanical components due to its lightweight yet durable nature. This helps reduce the weight of vehicles, increase fuel efficiency, and reduce emissions. 

Porsche has developed a 3D printed aluminum case for an electric car (Source: Porsche) 

Read more: SLM SOLUTIONS AND PORSCHE ACHIEVE HIGH-PERFORMANCE E-DRIVE HOUSING 

5. Metal 3D printed orthopedic hip replacement implant 

Metal 3D printing is transforming various industries by enabling the production of intricate parts with high precision and in a short time frame. This technology not only reduces costs and waste but also allows for product customization to meet the specific requirements of diverse fields such as healthcare, automotive, energy, aerospace, electronics, and manufacturing. 

5.1. Healthcare 

Metal 3D printing is revolutionizing the healthcare industry with innovative and customized solutions. This technology creates implants like artificial bones and joint replacements, improving biocompatibility and reducing recovery time. Complex medical devices such as surgical instruments and hearing aids are also manufactured with high reliability and performance. Moreover, 3D printing enables personalization of medical products, optimizing treatment and enhancing patients' quality of life. Additionally, metal 3D printing supports the creation of anatomical models for medical education and research. 

Metal 3D printed orthopedic hip replacement implant

5.2. Automotive 

In the automotive industry, metal 3D printing enables the production of complex and customized parts according to specific requirements. Automakers use this technology for prototyping, producing special tools and assembly parts. Even some companies have manufactured complete vehicles using 3D printing technology. 

READ MORE: BRINGING CLASSIC CADILLAC ELDORADO INTO 3D METAL PRINTING ERA  

5.3. Energy 

Metal 3D printing is being applied in the energy sector to manufacture parts for energy machinery and equipment, reducing production time and increasing efficiency. 3D-printed parts can be designed to optimize performance and durability, especially in harsh environments such as power plants and oil and gas rigs. 

Compressor blades designed and 3D printed by WÄRTSILÄ

5.4. Aerospace 

The aerospace industry utilizes metal 3D printing technology to produce lightweight yet extremely strong and precise parts, meeting stringent quality and safety requirements. 3D printing allows for the manufacturing of components with complex designs that are difficult to achieve through traditional methods. This helps reduce the weight of aircraft and spacecraft, thereby saving fuel and increasing flight performance.  
 

Metal 3D printed monolithic rocket thrust chamber

5.5. Electronics 

In the electronics industry, metal 3D printing is used to produce cooling components and electronic devices. This technology helps minimize overheating damage to electronic devices and increases design flexibility to meet the rapidly changing demands of the electronics market. 

Cold plate designed and simulated by Vinnotek 

Read detailed applications of metal 3D printing at: COLD PLATE WITH GYROID STRUCTURE REDUCES WORKING TEMPERATURE BY 30%

5.6. Manufacturing 

Metal 3D printing opens up numerous opportunities for the manufacturing industry by enabling the creation of products with complex shapes, optimizing manufacturing processes, and minimizing costs. This technology allows businesses to quickly produce prototypes, improve designs and products flexibly, and reduce waste compared to traditional methods. 

Read more: APPLICATIONS OF 3D METAL PRINTING IN TOP 4 INDUSTRIES 

6. Popular Metal 3D Printer Models 

Metal 3D printers using Selective Laser Melting (SLM) technology are becoming the top choice in many industries due to their ability to produce high-precision and high-quality products. Below are some popular metal 3D printer models: 

6.1. Nikon SLM Solutions 

Nikon SLM Solutions is one of the leading brands in the field of metal 3D printing. Models like the SLM 125 and SLM 280 stand out for their ability to print complex metal parts with high precision and exceptional performance. 

6.1.1. SLM 125 Printer 

The SLM®125 printer, with its compact size, high precision, and superior performance, is the perfect choice for applications requiring minimal metal powder usage. As the smallest model in the SLM Solutions lineup, the SLM®125 meets a wide range of needs, from rapid prototyping and small-batch production to mass production and scientific research. 

Specifications

Applications

Medical Applications: 

• Printing implants: The SLM 125 printer can produce small, precise parts, making it suitable for manufacturing implants such as joints, bone screws, and other medical devices. 
• Surgical instruments: Its high-resolution printing capability (with a layer thickness of 20 microns) allows for the production of intricate surgical instruments, meeting stringent requirements for precision and smooth surfaces. 

Aerospace Applications: 

• Aircraft components: The SLM 125 can print small, high-strength parts from materials like titanium and aluminum, aiding in the production of lightweight and durable aircraft components. 

Heat Exchange Applications: 

• Cooling components: ABB has redesigned cooling systems using SLM technology, reducing the cooling time of TPE significantly by up to 80%, from 30 seconds to just 6 seconds. This equates to a 75% reduction in the overall production cycle, from 19.6 seconds to 14.7 seconds. 

6.1.2. SLM 280 Printer 

The SLM®280 Production Series is the third generation of advanced metal 3D printers from SLM Solutions, delivering superior performance for businesses requiring high-productivity manufacturing systems. Equipped with a multi-laser system, automatic powder handling, and enhanced process control, the SLM®280 Production Series optimizes printing speed, product quality, and material efficiency. 

Specifications

Applications

Industrial Manufacturing Applications: 

• Engine components: The SLM 280 is used to print complex engine parts that require high heat and stress tolerance, thereby enhancing engine performance and lifespan. 
• Mold making: With its ability to print large and precise components, the SLM 280 supports the creation of accurate molds for casting and other manufacturing processes. 

Automotive Industry Applications: 

• Car parts: The SLM 280 can print automotive components such as engine parts, brake systems, and other load-bearing elements, ensuring high durability and safety. 

Explore the Top Metal 3D Printers of today: CURRENTLY POPULAR SLM METAL 3D PRINTER SERIES

6.2. Meltio 

Meltio is a company specializing in metal 3D printing using laser wire technology. They employ the Directed Energy Deposition method, which is considered safer and more reliable than other metal 3D printing methods since it does not use flammable metal powders. Meltio can print a variety of metal materials, including stainless steel, mild steel, and titanium alloys. 

Notable is the Meltio M450 metal 3D printer, designed for industries without requiring industrial infrastructure. It is affordable, safe, and easy to use. Ideal for creating small to medium-sized parts, the Meltio M450 allows users to produce very dense metal parts in a single step on a very compact footprint. 

Specification

Applications of the Meltio M450 Metal 3D Printer 

Industrial Manufacturing: 

• Aircraft parts: The Meltio M450 is used in the aerospace industry to produce complex and robust components from materials like titanium and nickel alloys. Notable parts include aircraft brackets, rocket nozzles, dual-material tubes, turbo blades, and connecting rods. 

Research and Development: 

• New material development: The ability to handle new and complex materials helps research and development centers test and create new materials with superior properties. The Meltio M450 can 3D print with various metal materials, including stainless steel, mild steel, and titanium alloys. 
• Rapid prototyping: It aids researchers and engineers in quickly developing and testing prototypes before mass production. 

Mass Production: 

• Small to medium parts: The Meltio M450 can print metal parts with a maximum size of 145 x 168 x 390 mm. This printer is suitable for producing parts for various industries, including aerospace, medical, automotive, and energy. 

6.3. TiTomic 

TiTomic is an Australian technology company known for its Kinetic Fusion technology, also known as Cold Spray, which allows metal 3D printing without heat application. 

D523 Model: The Titomic D523 is a specialized machine for repair work. With a compact size (550 x 1420 x 266mm) and a handheld metal spray nozzle, it allows precise repair work on parts. This machine features dual powder feed sources and operates on 230V AC 50/60Hz power, with the following specifications: 

Specifications

Applications of the D523 Printer 

The D523 printer has several important applications in additive manufacturing due to its advanced cold spray technology and flexible design. Here are some of the key applications: 

Repair and maintenance: 

• On-site repair: The D523 can be used to repair metal parts on-site without the need for disassembly or transportation to a factory, minimizing downtime and costs. 

• Industrial equipment maintenance: The ability to repair worn or damaged surfaces and components, helping to extend the life of equipment and machinery. 

Production of metal parts: 

• Rapid prototyping: The D523 can produce high-precision metal prototypes, allowing for testing and refinement of designs before mass production. 

• Production of small and complex parts: The ability to print small and complex parts with high strength, suitable for industries that require sophisticated and precise parts. 

Surface coating and protection: 

• Corrosion-resistant coatings: The machine can create corrosion-resistant coatings to protect metal parts from harsh environments, particularly useful in the aerospace, oil and gas, and marine industries. 

• Functional coatings: Create coatings that improve properties such as hardness, durability, and heat resistance, helping to improve the performance and lifespan of parts. 

6.4. HP 

HP is an American multinational technology corporation known for its products such as personal computers, printers, and laptops. As manufacturing technology advances, HP is also leading the way with its line of industrial metal 3D printers that use Metal Jet technology to create complex metal parts with high precision. 

HP Metal Jet S100 - Industrial metal 3D printer for mass production, helping to reduce costs, increase production speed, and create lighter and stronger metal products. HP Metal Jet 3D metal printing technology uses a binder jetting method to create 3D metal parts. 

Specifications

More detail: HP Metal Jet S100 Printing Solution 

The HP Metal Jet S100 3D metal printer has a wide range of applications across various industries, including: 

• Automotive: Produce high-quality, optimally designed, and time-saving automotive parts such as solenoid valves, key fobs, gear knobs, structural reinforcement for A-pillars, and more, especially for major brands like Volkswagen. 
• Industrial Manufacturing: Utilize for manufacturing industrial parts with flexible designs that enable efficient heat/fluid transfer, weight reduction, and cost savings. Notable parts include digital engine components, fluid distribution manifolds, air filters, and more. 

690V Air Filter/Circuit Breaker

• Hydraulics: Enhance the performance of hydraulic components like the S4 Pro Servo Valve (allowing more fluid flow in smaller, more complex spaces), fuel lines (complex near-lattice shape applications), and more. 
• Consumer Goods: Create high-quality, well-finished, creatively designed, and personalized products tailored to individual customers, such as watch cases, rings, pendants, golf clubs, and more. 

Learn more: Top 10 Frequently Asked Questions About Metal 3D Printing Technology

Vinnotek: Your Trusted Partner for 3D Printing Design and Simulation Solutions 

Metal 3D printing technology plays a key role in raising the quality in this field and optimize production costs for businesses. However, to exploit the full potential of 3D printing, professional design and simulation services are needed. 

Vinnotek emerges as a reliable partner in this domain, offering comprehensive 3D printing design and simulation services for critical parts in many industries, such as aerospace, automotive, energy, and medical. 

We not only bring the benefits of advanced 3D printing technology but are also the official representative of Nikon SLM Solutions - one of the world's leading 3D metal printer manufacturers and Titomic - a pioneer in large-scale additive manufacturing applications, such as tools, spare parts, and machine parts, replacing traditional manufacturing methods.  

With a combination of creativity and professionalism, we are committed to working with your business to optimize designs, reduce production costs, and improve work efficiency. 

Contact Vinnotek today to experience innovation and advancement in your industry! 

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