3D printing with metals - technologies and printers
3D metal printing is becoming increasingly popular. And this is not surprising: each metal printing material offers a unique combination of practical and aesthetic properties in order to meet the requirements of various products, whether it be prototypes, miniatures, jewelry, functional parts or even kitchen utensils.
The reasons for printing with metals are so compelling that 3D printing with metals is already being introduced into mass production. In fact, some 3D-printed parts have already caught up, and some have surpassed those produced by traditional methods in their properties.
The traditional production of metals and plastics is very wasteful - in the aircraft industry, for example, up to 90% of materials go to waste. The output, in some industries, is not more than 30% of the material used.
3D printing with metals consumes less energy and reduces waste to a minimum. In addition, a finished 3D printed product can be up to 60% lighter than a milled or cast part. The aviation industry alone will save billions of dollars in fuel - by reducing the weight of structures. But strength and lightness are also needed in other industries. Yes, and profitability, too.
3D metal printing at home
What can be done if there is a desire to try 3D printing with metal at home? Extremely high temperatures are required for metal printing; you are unlikely to be able to use a conventional FDM 3D printer for this, at least for now. The situation may change in a few years, but now this is not available for home 3D technology.
If you want to make metal-looking printouts at home, the best option is to use plastic containing metal particles.
Such as Colorfabb Bronzefill or Bestfilament Bronze .
These filaments contain a significant percentage of metal powders, but also enough plastic - for printing at low temperature with any 3D printer. At the same time, they contain a sufficient amount of metal to accordingly look, feel and have a weight close to the weight of a metal object.
Products made of a filament containing iron even become rusty under certain conditions, which adds credibility, but they will not be able to rust through and deteriorate - and this is their advantage over real metal objects.
The advantages of such materials:
- Unique print appearance
- Ideal for jewelry, figurines, household items and decor.
- High strength
- Very low shrinkage during cooling
- Heated table optional
Minuses:
- Low product flexibility, depending on print design
- Not considered safe in contact with food.
- Requires fine tuning of nozzle temperature and filament feed rate
- Post-processing of products is necessary - grinding, polishing
- Rapid wear of the extruder nozzle - filament with metal is very abrasive compared to conventional materials
The total print temperature range is usually 195 ° C - 220 ° C.
3D metal printing in industry
If you want to buy a 3D printer that prints real metal for use in the enterprise, then here are two news for you - good and bad.
The good news is that their range is wide enough and continues to expand - you can choose a device that meets any technical requirements. Further in the article you can verify this.
The bad news is one thing - prices. The cost of professional metal-printing printers starts at around $ 200,000 and grows indefinitely. In addition, even if you choose and purchase the most inexpensive of them, a separate blow will be the purchase of consumables, scheduled maintenance with the replacement of components, and repair. Do not forget about the staff and the costs of post-processing products. And at the stage of preparation for printing, you will need special software and people who can handle it.
If you are ready for all these expenses and difficulties - read on, we will present some very interesting samples.
https://youtu.be/20R9nItDmPY
3D metal printing - application
Some industrial sectors already use metal 3D printers , they have become an integral part of the production process, which an ordinary consumer may not be aware of:
The most common example are medical implants and dental crowns, bridges, prostheses, which are already considered the most optimal option for patients. Reason: They can be made faster and cheaper using a 3D printer and adapted to the individual needs of each patient.
The second, equally common example: jewelry . Most large manufacturers are gradually moving from 3D printing of molds and waxes to direct 3D printing with metal, and printing from titanium allows jewelers to create products of previously impossible design.
In addition, the aerospace industry is becoming more and more dependent on 3D-printed metal products. Ge-AvioAero in Italy is the world's first fully 3D printing factory to produce LEAP jet engine components.
The next industry using 3D printers for metal is the auto industry. BMW, Audi, FCA are already seriously considering the application of technology in mass production, and not only in prototyping, where they have been using 3D printing for many years.
It would seem - why reinvent the wheel? But here, 3D printing with metal has found application. For several years now, manufacturers of bicycle components and frames have been using 3D printing. Not only in the world, but also in Russiait gained distribution. The manufacturer of exclusive bicycles Triton is completing a project with a 3D-printed element of a titanium frame, which allowed to reduce its weight without compromising strength.
But before 3D printing with metals really captures the world, it will be necessary to overcome several serious problems. First of all, it is the high cost and low speed of production of large batches by this method.
3D metal printing - technology
Much can be said about the use of metal-printing 3D printers. There is a specificity, but the basic issues are the same as with any other 3D printers: software and hardware limitations, optimization of materials and printing with several materials. We will not talk about software much, we only mention that the largest publishers, such as Autodesk, SolidWorks and SolidThinking, all develop software products for use in bulk metal printing, so that users can realize a product of any imaginable form.
Recently, examples have appeared that 3D-printed metal parts can be as strong as traditionally manufactured metal components, and in some cases even surpass them. Created using DMLS, products have the same mechanical properties as solid cast counterparts.
Let's look at the available metal technologies of 3D printing:
Process # 1: Layer Powder Fusion
The 3D printing process with metals, which the largest companies use today, is known as fusion or sintering of the powder layer. This means that a laser or other high-energy beam fuses together particles of a uniformly distributed metal powder, creating product layers, one after the other.
There are eight major manufacturers of 3D metal printing printers in the world, most of them located in Germany. Their technologies are abbreviated as SLM (selective laser melting) or DMLS (direct sintering of metal by laser).
Process # 2: Binder Jetting
Another professional method with layer-by-layer bonding is the bonding of metal particles for subsequent firing in a high-temperature furnace, where the particles are fused under pressure, forming a single metal whole. The print head applies the bonding solution to the powder substrate in layers, like a normal printer, on sheets of paper, after which the product is sent for firing.
Another similar but different technology, which is based on FDM printing - mixing metal powder into a metal paste. Using pneumatic extrusion, a 3D printer extrudes it, much like a building 3D printerdoes this with cement to form 3D objects. After the desired shape is printed, the objects are also sintered in the furnace. This technology uses Mini Metal Maker - perhaps the only more or less affordable 3D printer for metal printing ($ 1600). Add the cost of a small roasting stove.
Process # 3: Fusion
You might think that among metal printing technologies there is no similar to ordinary FDM, however, this is not entirely true. You will not be able to melt a metal thread in the hot end of your 3D printer, but large manufacturers own this technology and use it. There are two main ways to print with all-metal material.
One of them is called DED (Directed Energy Deposition), or laser cladding. It uses a laser beam to fuse metal powder, which is slowly released and deposited from the extruder, forming the layers of the object using an industrial manipulator.
This is usually done inside a closed chamber, however, using the example of MX3D, we see the possibility of implementing such a technology in the construction of a real full-sized bridge, which should be printed in 2017 in Amsterdam.
Another is called EBM (Electron Beam Manufacturing - electron beam production), it is a technology of forming layers of metal raw materials under the influence of a powerful electron beam, with its help create large and very large structures. If you do not work in the defense complex of the Russian Federation or the USA, you are unlikely to see this technology alive.
A couple of new, barely emerging technologies used so far only by their creators are presented below - in the section on printers.
Used metals
Ti - Titanium
Pure titanium (Ti64 or TiAl4V) is one of the most commonly used metals for 3D printing, and certainly one of the most versatile, as it is both durable and lightweight. It is used both in the medical industry (in personalized prosthetics), and in the aerospace and automotive industries (for the manufacture of parts and prototypes), and in other fields. The only catch - it has a high reactivity, which means - it can easily explode when it is in the form of a powder, and must be used for printing only in an argon inert gas environment.
SS - Stainless Steel
Stainless steel is one of the most affordable metals for 3D printing. At the same time, it is very durable and can be used in a wide range of industrial and artistic industries. This type of steel alloy, containing cobalt and nickel, has high elasticity and tensile strength. 3D printing with stainless steel is used mainly only in heavy industry.
Inconel - Inconel
Inconel is a modern superalloy. It is manufactured by Special Metals Corporation and is a patented trademark. It consists mainly of nickel and chromium, and has high heat resistance. It is used in the oil, chemical and aerospace industries (for example: to create distribution nozzles, on-board “black boxes”).
Al - Aluminum
Due to its inherent lightness and versatility, aluminum is a very popular metal for use in 3D printing. It is usually used in the form of various alloys, making up their basis. Aluminum powder is explosive and is used in printing in an argon inert gas environment.
CoCr - Cobalt Chrome
This metal alloy has a very high specific strength. It is used both in dentistry - for 3D printing of dental crowns, bridges and arch prostheses, and in other areas.
Cu - Copper
With rare exceptions, copper and its alloys - bronze, brass - are used for casting using burnable models, and not for direct printing with metal. This is because their properties are far from ideal for use in industrial 3D printing, they are more often used in arts and crafts. With great success, they are added to the plastic filament - for 3D printing on conventional 3D printers.
Fe - Iron
Iron and magnetic iron are also mainly used as additives to PLA filaments. In large-scale industry, pure iron is rarely used, but we wrote about steel above.
Au, Ag - Gold, silver and other precious metals
Most fused powder layers of 3D printers can work with precious metals such as gold, silver and platinum. The main task when working with them is to verify the optimal consumption of expensive material. Precious metals are used in 3D printing of jewelry and medical products, as well as in the manufacture of electronics.
3D metal printers
# 1: Sciaky EBAM 300 - titanium rod
For printing really large metal structures, Sciaky's EBAM is the best choice. This device can be of any size, to order. It is used mainly in the aerospace and defense industries of the United States.
As a production model, Sciaky sells the EBAM 300. It has a workspace size with sides of 5791 x 1219 x 1219 mm.
The company claims the EBAM 300 is one of the fastest commercially available industrial 3D printers. The structural elements of aircraft, the production of which, according to traditional technologies, could take up to six months, are now printed within 48 hours.
Sciaky's unique technology uses a high power cathode-ray gun to melt a titanium filament 3 mm thick, with a standard deposition rate of about 3-9 kg / h.
# 2: Fabrisonic UAM - Ultrasound
Another 3D printing method for large metal parts is the Ultrasound Additive Manufacturing Technology (UAM - Ultrasonic Additive Manufacturing Technology) from Fabrisonic. The brainchild of Fabrisonic is a three-axis CNC machine with an additional welding head. The metal layers are first cut and then welded together using ultrasound. The largest Fabrisonic 3D printer is the “7200”, with a build volume of 2 x 2 x 1.5 m.
# 3: Laser XLine 1000 - metal powder
One of the largest metal powder printing 3D printers on the market has long been the Concept Laser's XLine 1000. It has an assembly area of 630 x 400 x 500 mm in size, and takes up space as a small house.
The German company, which is one of the suppliers of 3D printers for giant aerospace companies such as Airbus, recently introduced a new printer, the XLine 2000.
2000 has two lasers and an even larger build volume of 800 x 400 x 500 mm. This machine, which uses the patented LaserCUSING technology (type of selective laser melting), can create objects from alloys of steel, aluminum, nickel, titanium, precious metals and from some pure materials (titanium and steel.)
All the major players in the 3D metal printing market have such machines: EOS, SLM, Renishaw, Realizer and 3D Systems, as well as Shining 3D, a rapidly developing company from China.
# 4: M Line Factory - a modular 3D factory
Displacement: 398.78 x 398.78 x 424.18 mm
From 1 to 4 lasers, 400 - 1000 W of power each.
The M Line Factory concept is based on the principles of automation and interaction.
M Line Factory, from the same Concept Laser, and working on the same technology, does not focus on the size of the workspace, but on the convenience of production - it is a modular architecture apparatus that divides production into separate processes so that these processes can occur simultaneously, and not sequentially.
This new architecture consists of 2 independent machine nodes:
M Line Factory PRD (Production Unit - Production Unit) The
Production Unit consists of 3 types of modules: dispensing module, printing module and overflow module (tray for finished products). All of them can be individually activated and do not form one continuous unit of equipment. These modules are transported through a tunnel system inside the machine. For example, when a new powder is supplied, an empty powder storage module can be automatically replaced with a new one without interrupting the printing process. Finished parts can be moved outside the machine and immediately automatically replaced by the following tasks.
M Line Factory PCG (Processing Unit)
It is an independent data processing unit that has an integrated sieving and powder preparation station. Unpacking, preparation for the next print job and screening take place in a closed system, without operator intervention.
# 5: ORLAS CREATOR - a 3D printer ready to go
The creators of ORLAS CREATOR position this 3D printer as the most affordable, easy to use and ready to use, requiring no installation of additional components and third-party programs, capable of printing directly from a complete CAD / CAM file of their own design.
All the necessary components are installed in a relatively compact case, which needs a space of 90x90x200 cm. It does not take up much space, although it looks impressive, and weighs 350 kg.
As can be understood from the table given by the manufacturer, the metal powder is sintered by a rotating laser system, with layers of 20-100 microns thick and with a “pixel” size of only 40 microns, in an atmosphere of nitrogen or argon. You can connect it to a regular household electrical network if your wiring can withstand a load of 10 amperes. Which, however, does not exceed the requirements of an average washing machine.
Laser power - 250 watts. The working area is a cylinder 100 mm in diameter and 110 in height.
# 6: FormUp 350 - Powder Machine Part Method (PMPM)
Powder Machine Part Method (PMPM) FormUp 350 was created by AddUp, a joint project between Fives and Michelin. This is the latest 3D metal printing machine, first introduced in November at Formnext2016.
The principle of operation of this 3D printer is the same as that of the colleagues mentioned above, but its main feature is different in that it consists in its inclusion in PMPM.
The printer is designed specifically for industrial use, in 24/7 mode, and is designed specifically for this pace of work. The PMPM system includes quality control of all components and materials, at all stages of their production and distribution, which should guarantee consistently high performance indicators, which Michelin has vast experience over many years.
# 7: XJET - NanoParticle Jetting - metal inkjet printing
The technology of injection of nanoparticles involves the use of special sealed cartridges with a solution in which a suspension of metal nanoparticles is located.
Nanoparticles are deposited and form the material of the printed product.
Given the claimed features of the technology (the use of metal particles of nanoscale size), it is easy to believe the creators of the device when they claim its unprecedented accuracy and print resolution.
# 8: VADER Mk1 - MagnetoJet - metal inkjet printing
Zack Vader’s MagnetoJet technology is based on the study of magnetic hydrodynamics, and more specifically, the ability to control molten metal using magnetic fields. The essence of the development is that a drop of strictly controlled size is formed from molten aluminum, and these drops are printed.
The size of such a droplet is from 200 to 500 microns, printing occurs at a speed of 1000 drops per second. The working area of the printer: 300 mm x 300 mm x 300 mm
Working material: Aluminum and its alloys (4043, 6061, 7075). And, while it is only aluminum, the printer is 2 times faster than powder ones and up to 10 times cheaper.
In 2018, the release of Mk2 is planned, it will be equipped with 10 printheads, which should give a print speed increase of 30 times.
# 9: METAL X - ADAM - atomic diffusion
Markforged introduced the new 3D metal printing technology - ADAM, and the 3D printer using this technology - Metal X.
ADAM (Atomic Diffusion Additive Manufacturing) - atomic diffusion technology. Printing is performed with metal powder, where the metal particles are coated with a synthetic binder, which is removed after printing, allowing the metal to merge into a single whole.
The main advantage of the technology is the absence of the need to use ultra-high temperatures directly in the printing process, which means that there are no restrictions on the refractoriness of the materials used for printing. Theoretically, the printer can create 3D models from heavy-duty tool steels - now it is already printing with stainless steel, and in development titanium, Inconel and D2 and A2 steel.
The technology allows you to create parts with a complex internal structure, such as in honeycombs or in porous bone tissues, which is difficult with other 3D printing technologies, even for DMLS.
Product size: up to 250mm x 220mm x 200mm. Layer height - 50 microns.
That look, soon it will be possible to print a high-quality knife - from scratch, in a couple of hours, giving it any most intricate design.
Want more interesting news from the world of 3D technology?
Subscribe to us in the social. networks:
