{"id":3736,"date":"2025-08-07T20:08:28","date_gmt":"2025-08-07T12:08:28","guid":{"rendered":"https:\/\/chiggofactory.com\/?p=3736"},"modified":"2025-08-07T20:08:32","modified_gmt":"2025-08-07T12:08:32","slug":"guide-to-metal-3d-printing","status":"publish","type":"post","link":"https:\/\/chiggofactory.com\/de\/guide-to-metal-3d-printing\/","title":{"rendered":"Beginner\u2019s Guide to Metal 3D Printing"},"content":{"rendered":"\n

Metal 3D printing is advancing rapidly\u2014with faster build speeds, better material performance, and wider application areas. This guide will show you how to get the most out of metal additive manufacturing(AM): we will talk about the main types of metal 3D printing technologies, the common materials, and what it all costs. We will also compare metal AM with subtractive (CNC machining<\/a>) and formative (metal casting) methods so you can choose the right process for your part, your budget, and your timeline.<\/p>\n\n\n\n

What Is Metal 3D Printing ?<\/h2>\n\n\n\n
\"metal<\/figure>\n\n\n\n

Similar to all other 3D printing processes (such as polymer 3D printing), metal 3D printers build parts by adding material a layer at a time based on a digital 3D design \u2014 hence the term additive manufacturing. Only this time, the process uses metal powder, wire, or polymer\u001ebound filament instead of plastics.<\/p>\n\n\n\n

This way, parts can be built with geometries that are impossible to manufacture with traditional methods and without the need for specialized tooling such as molds or cutting tools. Just as important, increasing geometric complexity has little impact on build cost, so organic, topology\u001eoptimized structures are practical. The resulting parts are lighter (typically a 25%\u201350% weight reduction) and often stiffer, which is critical for aerospace and other high\u001eperformance fields.<\/p>\n\n\n\n

This design freedom also enables assembly consolidation: multiple components,and all their fasteners, joints, and leak paths,can become a single printed part that performs several functions at once. Labor drops, lead times shrink, and maintenance is simpler because there is less to assemble, align, or service. That said, metal 3D printing is still expensive compared to many traditional methods, and it doesn\u2019t yet compete on unit cost at higher volumes.<\/p>\n\n\n\n

A Brief History of Metal 3D Printing<\/h2>\n\n\n\n
\"history<\/figure>\n\n\n\n

In the late 1980s, Dr. Carl Deckard at the University of Texas developed the first laser sintering 3D printer, initially designed for plastics. This technology became the basis for Selective Laser Sintering (SLS), a method that would later extend to metal 3D printing.<\/p>\n\n\n\n

In 1991, Dr. Ely Sachs from MIT introduced a 3D printing process now known as binder jetting. This method of metal binder jetting was licensed to ExOne in 1995.<\/p>\n\n\n\n

In 1995, the Fraunhofer Institute in Germany filed the first patent for laser melting of metals, which laid the foundation for Selective Laser Melting (SLM), one of the most widely used methods for metal 3D printing today. During this period, companies like EOS and various universities played key roles in further developing the technology.<\/p>\n\n\n\n

Metal 3D printing grew slowly in the early 2000s due to the high cost of equipment and materials. However, around 2012, as the patents for key technologies like SLM, DMLS, and EBM began to expire, licensing fees dropped, opening the door for new competitors. This shift sparked innovation and attracted major investments from companies like GE, HP, and DMG Mori, lowering costs and accelerating adoption across various industries.<\/p>\n\n\n\n

Today, according to the Precedence Research report<\/a>, the global metal 3D printing market was valued at USD 9.66 billion in 2024 and is projected to grow from USD 12.04 billion in 2025 to USD 87.33 billion by 2034, with a CAGR of 24.63%. The market is driven by demand for rapid prototyping, customized and complex components, and growing usage in aerospace and automotive sectors.<\/p>\n\n\n\n

Types of Metal 3D Printing Technologies<\/h2>\n\n\n\n
\"3D<\/figure>\n\n\n\n

There are many metal 3D printing technologies on the market, but four of the most widely used are Powder Bed Fusion (PBF), Binder Jetting, Metal Fused Deposition Modeling (Metal FDM), and Directed Energy Deposition (DED). Broadly, they fall into two mechanisms: melting and sintering.<\/p>\n\n\n\n

PBF and DED melt metal feedstock (powder or wire) with high\u001eenergy sources\uff0clike lasers, electron beams, or arcs, to produce near\u001efully dense parts. By contrast, Metal FDM and Binder Jetting first create a \u201cgreen\u201d part with a polymer binder, then debind and sinter it below the melting point. Final density is typically lower than fully melted processes, and additional post\u001eprocessing is almost always required.<\/p>\n\n\n\n

Powder Bed Fusion (PBF)<\/h3>\n\n\n\n
\"Powder<\/figure>\n\n\n\n

Powder Bed Fusion (PBF) is widely regarded as the most commonly used metal 3D printing family. Among these, Selective Laser Melting (SLM)<\/strong> and Direct Metal Laser Sintering (DMLS)<\/strong>, which have been in use for over 20 years, are the most technologically mature metal 3D printing processes today, followed by Electron Beam Melting (EBM)<\/strong>, another key method, particularly used for titanium alloys in aerospace and medical applications.<\/p>\n\n\n\n

The PBF process begins by preheating the build chamber, which is first filled with an inert gas, to an optimal temperature. A thin layer of metal powder is then spread across the build platform. The laser (in SLM and DMLS) or electron beam (in EBM) is directed at the powder bed, selectively melting or fusing the powder particles according to the part's design. The particles fuse together to form the first layer, and the platform is then lowered slightly. A new layer of powder is spread over the previous one, and the process is repeated layer by layer until the part is fully built.<\/p>\n\n\n\n

Since build temperatures are very high (often >1000\u202f\u00b0C for many alloys), supports are usually required to hold the part in place and prevent warping from thermal stress. After cooling, the excess unmelted powder is removed (brushed, blasted, or vacuumed off), and the supports are removed by cutting or wire EDM.<\/a> The part is then heat\u001etreated to relieve residual stresses and enhance material properties. Finally, depending on requirements, the part may need additional finishing such as CNC machining, polishing<\/a>, or other surface treatments to achieve the desired surface quality and dimensional accuracy.<\/p>\n\n\n\n

Characteristics of Common Powder Bed Fusion Methods<\/strong><\/p>\n\n\n\n

Here\u2019s a detailed comparison table for the three main PBF metal 3D printing technologies:<\/p>\n\n\n\n

Property<\/strong><\/strong><\/td>Selective Laser Melting (SLM)<\/strong><\/strong><\/td>Direct Metal Laser Sintering (DMLS)<\/strong><\/strong><\/td>Electron Beam Melting (EBM)<\/strong><\/strong><\/td><\/tr>
Energy Source<\/strong><\/td>Laser<\/td>Laser<\/td>Electron Beam<\/td><\/tr>
Materials Used<\/strong><\/strong> <\/td>Spherical metal powders with a single melting temperature; include aluminum alloys, titanium, stainless steel, tool steel, and certain alloys <\/td>Spherical metal powders with variable melting points; include stainless steel, titanium alloys, nickel alloys, precious metals, and tool steels <\/td>Spherical metal powders such as titanium alloys, cobalt-chromium alloys, nickel superalloys, and other high-performance materials<\/td><\/tr>
Process<\/strong><\/td>Laser fully melts the powder to create dense parts<\/td>Laser sintering (melts powder but does not fully liquefy it)<\/td>Electron beam melts powder in a vacuum environment<\/td><\/tr>
Build Volume<\/strong><\/strong> <\/td>Typically small to medium (varies by machine) <\/td>Typically small to medium (varies by machine) <\/td>Typically larger build volumes available compared to SLM\/DMLS <\/td><\/tr>
Build Speed<\/strong><\/td>Moderate (depends on laser power and part complexity)<\/td>Moderate (varies with material and part size)<\/td>Slower (due to the use of electron beam and vacuum environment)<\/td><\/tr>
Printed Part Properties<\/strong><\/td>Internal porosity, less than 0.2 - 0.5%; high density and excellent mechanical strength<\/td>The part properties are similar to SLM, but slight porosity may be more noticeable due to the sintering process<\/td>The porosity is generally low, but it can be slightly higher than SLM due to the slower build speed and larger layer thickness in the process<\/td><\/tr>
Dimensional Accuracy<\/strong><\/td>\u00b1 0.1 mm<\/td>\u00b1 0.1 mm<\/td>\u00b1 0.1 mm<\/td><\/tr>
Typical Build Size<\/strong><\/td>250 x 150 x 150 mm
( up to 500 x 280 x 360 mm)<\/td>		250 x 150 x 150 mm
( up to 500 x 280 x 360 mm)<\/td>		500 x 500 x 380 mm or larger<\/td><\/tr>
Common Layer Thickness<\/strong><\/td>20-50\u03bcm<\/td>20-50\u03bcm<\/td>50-150 \u03bcm<\/td><\/tr>
Support<\/strong><\/td>Always required<\/td>Always required<\/td>Always required<\/td><\/tr>
Typical Surface Roughness<\/strong><\/td>Ra 8 - 10\u03bcm<\/td>Ra 8 - 10\u03bcm<\/td>Ra 20-60 \u03bcm<\/td><\/tr>
Cost Per Part<\/strong><\/td>$$$$$<\/td>$$$$$<\/td>$$$$$$<\/td><\/tr>
Key Applications<\/strong><\/td>Parts with high geometric complexity (organic, topology optimized structures) that require excellent material properties for increasing the efficiency of the most demanding applications<\/td>Similar to SLM<\/td>High-performance applications that require strong, resilient parts, particularly in aerospace and medical implants, where titanium alloys and other high-strength materials are needed<\/td><\/tr><\/tbody><\/table><\/figure>\n\n\n\n

Binder Jetting<\/h2>\n\n\n\n
\"Binder<\/figure>\n\n\n\n

Binder Jetting was originally used to create full-color prototypes and models from sandstone. Over time, it has gained popularity for manufacturing metal parts, particularly due to its batch production capabilities. During the metal binder jetting process, a thin layer of metal powder is spread across the build platform. A carriage equipped with inkjet nozzles then passes over the powder bed, depositing droplets of a binding agent (typically a mixture of polymer and wax) to bond the metal particles together. Once a layer is completed, the build platform moves down, and a new layer of powder is applied. This process repeats until the entire part is built.<\/p>\n\n\n\n

The printing step in metal binder jetting occurs at room temperature, eliminating issues like thermal effects such as warping and internal stresses that can occur in processes like DMLS and SLM. Support structures are not required. However, the printed part remains in a \"green\" state, meaning it is still fragile and requires further processing.<\/p>\n\n\n\n

There are two common post-processing steps used to transform the \"green\" part into a fully solid metal component:<\/p>\n\n\n\n