Embracing the Potential of 3D Metal Printing Services
Metal 3D printing can produce fully functional prototypes and production parts for the right applications. As a result, it can shortcut the process of machining or injection molding.
For example, consider a spring that triggers airbag inflation in an automobile accident. Conventional manufacturing can take weeks to produce a single unit.
Benefits of 3D Metal Printing
3D printing is helping organizations become more dynamic and responsive by compressing product timelines. Using a metal 3D printer enables manufacturers to take a design straight from a CAD file and produce functional parts much more quickly, saving time and money in the process. 3D printing also produces less waste material, making it a more environmentally responsible process than traditional manufacturing.
Whether it’s to create form-fit and function prototypes, injection-molding models, tooling patterns or jigs, 3D printing provides an alternative to more conventional processes that can be less expensive, quicker, and more accurate. And, because of the wide variety of metals available for 3D printing, there are an almost endless number of creative products that can be produced—everything from bicycle frames to robot parts.
One of the biggest advantages of metal 3D printing is that the process can produce complex geometries, pushing the boundaries of what can be manufactured by traditional methods. For example, traditional manufacturing can only produce parts with a maximum angle of 45 degrees, but 3D printing allows for print angles as low as 10 degrees. This allows for more intricate designs and structures and gives designers greater freedom to experiment with innovative forms that would be impractical or impossible to create through traditional methods.
Another advantage is that unlike CNC machining, which can often produce up to 90% of a part in scrap, metal AM wastes less than 5%—often less than 1%. This makes metal AM a more cost-effective and environmentally friendly alternative to other methods.
The 3D printing industry is still evolving, with new players emerging every year and a variety of different printer technologies and processes. Italian company 3D4MEC, for instance, developed two metal 3D printers that use laser powder bed fusion technology, the 3D4STEEL printer for steel and the 3D4BRASS for brass (a copper and zinc alloy). Both systems offer flexibility for a range of applications from production of support structures for aircraft and robotic arms to prototyping and pre-series manufacture.
In addition to the new printers, several on-demand 3D metal printing services have emerged that offer a wide range of materials and 3D printer technologies. Some of these companies even provide post-processing services and a full suite of engineering and design capabilities. To find the right company for your needs, consider a few important factors, such as service area, the ability to handle large-volume orders, and the type of printing technology offered.
A service that offers both a wide range of materials and several types of printing technologies is likely to be more competitive in terms of price, speed, and quality. In addition, a service that offers more advanced post-processing techniques such as electroplating and anodizing can further improve the mechanical properties and aesthetics of finished parts. Finally, a service that offers customer support and consultation with engineers can be an asset for companies that are new to the process and may need help establishing a viable workflow. Moreover, a service that can respond to requests faster will be more likely to keep customers happy.
Advantages of 3D Metal Printing
When compared to traditional manufacturing processes, 3D metal printing can cut production time and cost significantly. This is because of the reduced labor, tools, and material that are needed to produce a functional prototype or final part. This makes it possible for organizations to compress timelines and reduce the distance between a CAD design and a finished product.
Another major advantage of metal 3D printing is that it can be used to create complex geometries that push the limits of what is possible with conventional manufacturing. This can lead to groundbreaking design innovations, creating products that were never before possible or even feasible.
A great way to take advantage of this is by working with a 3D printer manufacturer that offers a range of materials and printing technologies. This will give you a wide range of options to create the best possible part for your specific application, such as direct metal laser sintering (DMLS), laser powder bed fusion (LPBF), and selective laser melting (SLM); or specialities like metal binder jetting, cold spraying, and metal lithography.
In addition to having a range of printing technology options, many companies also offer design services and helpful advice. For example, Sandvik, with over a century of experience in metal and 3D printing, has an online quoting platform that allows users to upload their files for evaluation. This service can provide useful tips on designing for metal printing, information on the maximum size that can be printed, estimated delivery times, and other important details.
As an added benefit, 3D printing is an environmentally-friendly process that produces less waste than CNC machining or traditional casting. This is because it uses a smaller amount of energy and generates significantly less scrap. The low rate of waste makes it a very efficient production method and an ideal alternative to traditional manufacturing.
There are some trade-offs with using 3D metal printing, however. For instance, there is a limit to the strength of metals that can be printed and certain materials may require additional post-processing. The best option for a particular application will depend on the mechanical and aesthetic qualities of the final part.
As more organizations become comfortable with the capabilities of 3D printing, they will be able to make smarter choices about which print methods and materials to use. By balancing these factors, they can ensure that they are getting the most out of this revolutionary technology. This will result in high-quality, strong, and lightweight parts that are perfect for their intended purpose. In the future, this could lead to a more efficient and affordable manufacturing process for businesses in a wide variety of industries. This is one of the reasons why so many companies are embracing the potential of metal 3D printing.
