Metal 3D Printing

Metal 3D printing builds fully dense metal parts layer-by-layer from powder or wire, enabling complex internal features with higher cost and post-processing needs.

Overview

Metal 3D printing (metal additive manufacturing) creates parts by fusing metal powder or depositing metal feedstock in layers. Common production routes include laser powder bed fusion (DMLS/SLM), electron beam melting (EBM), binder jetting with sintering, and direct energy deposition (DED). It excels at geometries that are difficult or impossible to machine: internal channels, lattices, part consolidation, and weight-optimized structures.

Choose it for prototypes and low-to-mid volumes where performance and geometry drive value more than piece price. Typical tradeoffs are higher unit cost, longer lead times, and mandatory post-processing: support removal, heat treat/HIP (often), machining of datum surfaces, and finishing. Expect anisotropic properties and residual stress considerations, plus tighter constraints on minimum wall thickness, overhang angles, and toleranced bores/threads (often best machined after print).

Common Materials

  • Ti-6Al-4V
  • Inconel 718
  • 316L Stainless Steel
  • 17-4 PH Stainless Steel
  • AlSi10Mg
  • CoCr

Tolerances

±0.005"

Applications

  • Conformal-cooled injection mold inserts
  • Lightweight aerospace brackets
  • Patient-specific orthopedic implants
  • Rocket engine injectors
  • Heat exchangers with internal channels
  • Turbomachinery housings with integrated features

When to Choose Metal 3D Printing

Pick metal 3D printing when geometry complexity, internal features, or part consolidation outweigh higher per-part cost. It fits best for prototypes through low-to-mid volumes, especially for high-value alloys and weight- or thermal-performance-driven parts. Plan on secondary operations to hit critical datums, sealing surfaces, and tight-fit features.

vs CNC machining

Choose metal 3D printing when the part needs internal channels, lattices, or consolidated assemblies that can’t be economically machined. It also makes sense when buy-to-fly would be extreme for titanium or nickel alloys, even after adding finish machining.

vs Investment casting

Choose metal 3D printing when you need rapid iteration without tooling, or when features like thin lattices and complex internal passages drive performance. It’s a strong fit for low volumes where tooling amortization would dominate cost.

vs Plastic 3D Printing

Choose metal 3D printing when the part must carry structural load, run at elevated temperature, resist wear/corrosion, or meet metal material specs. It also enables production-intent metal prototypes where plastic prints only validate form/fit.

vs Composites 3D Printing

Choose metal 3D printing when you need isotropic-ish metallic behavior, high compressive strength, conductivity/heat transfer, or weldable/inspectable metal hardware. It’s also preferable for threaded interfaces, sealing surfaces, and high-temperature environments where polymers and many composites struggle.

vs Metal injection molding (MIM)

Choose metal 3D printing when volumes are low or design changes are likely, since MIM requires tooling and benefits from stable, high-volume production. Metal AM also supports larger parts and more complex internal features than typical MIM geometries.

Design Considerations

  • Identify critical datums and leave machining stock on those surfaces for post-print finishing
  • Avoid deep blind holes, tight threads, and precision bores as-printed; model them for drilling/tapping/reaming after print
  • Minimize supports by orienting to reduce overhangs; add self-supporting angles, ribs, or chamfers where possible
  • Use consistent wall thickness and avoid long, thin cantilevers to reduce distortion and improve yield
  • Include powder escape holes for enclosed cavities and internal channels, sized for the chosen process
  • Call out material, heat treat/HIP, and inspection requirements clearly (CT, density, surface finish) to get accurate quotes