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As we moved into the fourth industrial revolution, the manufacturing process has become more automated, increasing scalability and efficiency. Additionally, there is less scope for human errors, leading to improved geometrical precision. However, in this era, the most impactful production technology that has taken the world by storm is 3D printing. Who would have imagined you could create a 3D object from a simple AutoCAD drawing?
Today, 3D printing is not restricted to plastics and resins, but it applies to metals like aluminum, titanium, cobalt, bronze, etc. Also, alloys like stainless steel are extensively used in 3D printing services. Manufacturers have unlocked the power of digital production, introducing a phenomenal transformation in the industry.
In recent times, most industries have relied on 3D printing for the production of parts and prototypes due to reduced labor involvement, fewer design flaws, enhanced surface finishes, low wastage, and rapid production speed. In other words, through 3D printing of metals, you can finally minimize post-processing and labor costs!
So, today, we are here to discuss metal 3D printing and how it has emerged as a true winner in the manufacturing sector.
Predominant Metal 3D Printing Technologies
The common principle of 3D printing is creating a part layer by layer. Hence, it is an additive manufacturing procedure, unlike CNC machining, where objects are extracted by removing parts of a giant material sheet. Metal 3D printing is primarily categorized into two forms- powder bed fusion (PBF) and direct energy deposition (DED). Let’s take a look at these processes.
- Powder Bed Fusion (PBF)- In powder bed fusion, finely powdered metal is spread across the build platform. Then, you selectively apply a powerful laser beam to melt and fuse the metal particles. As a layer forms, the build platform lowers, and the process repeats. PBF technology is available in two distinctive types- selective laser sintering (SLS) and direct metal laser sintering (DMLS). SLS and DMLS are conceptually similar. However, they differ only in the sintering material used. SLS uses a single metal, but DMLS uses multiple metal powders with different melting points. It means you can use alloys in DMLS. Aluminum 3D printing service relies on SLS to produce parts and products with superior density, design accuracy, and material consistency. You may require post-processing for customized finishes.
- Direct Energy Deposition- It is also an additive manufacturing process where powdered or metal filaments are melted and fused as they are deposited on the build platform. Typically, in DED processes, the metal is fed into a narrow nozzle, which is heated up using an electric or laser beam, plasma, or electric arc. As the metal melts, it is slowly deposited on the build platform layer by layer. The popular DED technologies include direct metal deposition (DMD), electron beam additive manufacturing (EBAM), etc. Metals like aluminum, copper, tungsten, titanium, stainless steel, nickel alloys, etc., are used in DED 3D printing.
The Popular Applications of Metal 3D Printing
As we said, the metal 3D printing service has been widely adopted by various industries to manufacture products with impeccable design accuracy, consistency, mechanical properties, and scalability. Hence, it is preferred for the following applications:
- Small-Scale Customized Parts- The ability to make easy design iterations lets you manufacture specialty parts in low volume. The enormous flexibility of the technology assures rapid production of custom parts and end-use products at cost-effective prices.
- Functional Prototypes- Metal 3D printing has eased rapid prototyping, where you can repeatedly manufacture prototypes in a single cycle. Additionally, the material consistency and design accuracy remain seamless, enabling faster delivery to the market.
- Decorative Pieces- If you think the metal showpieces in a shop are handcrafted, then you are wrong! Most often, these intricate and enticing decorative artifacts are created through 3D printing.
- Jewelry- Not all the necklaces, bangles, or earrings you find in the market are actually made through hard tooling. Today, metal 3D printing is prevalently preferred to create exquisite jewelry pieces.
- Medical Implants- From dental implants to joint prosthetics, a significant section of the medical industry relies on metal 3D printing. The best part is that it has improved surgical technology, and the healing is much faster.
So, now that you know about 3D printing services, we hope you recognize its influence on the world’s economy. The future has more to see!
