Metal 3D Printing

Metal 3D printing builds complex, fully dense metal parts layer by layer, enabling internal channels and lattices with minimal tooling at low to medium volumes.

Overview

Metal 3D printing creates functional metal parts by selectively melting or binding metal powder in thin layers, using processes like laser powder bed fusion, EBM, binder jetting, and DED. It excels at intricate geometries that are difficult or impossible to machine or cast, such as internal cooling channels, lattice structures, and topology-optimized brackets.

Engineers typically choose metal additive manufacturing for low to medium production volumes, fast iteration on complex designs, and lightweight structures with high strength-to-weight ratios. Expect good mechanical properties and near-wrought densities, but plan for support removal, heat treatment, and post-machining of critical surfaces. Tradeoffs include higher material and machine costs, limited build envelope, rougher as-printed surfaces, and tighter design rules around wall thickness, overhangs, and support structures. When leveraged correctly, metal 3D printing can consolidate assemblies, reduce part count, and dramatically shorten lead times for complex metal components.

Common Materials

  • 17-4 PH stainless steel
  • 316L stainless steel
  • Ti-6Al-4V
  • Inconel 718
  • AlSi10Mg
  • Maraging steel 18Ni300

Tolerances

±0.003"–±0.010" on as-printed features; tighter after machining critical surfaces

Applications

  • Conformal-cooled injection mold inserts
  • Lightweight aerospace brackets
  • Turbine and compressor blades
  • Custom orthopedic implants
  • Lattice heat exchangers
  • Topology-optimized drivetrain or suspension components

When to Choose Metal 3D Printing

Choose metal 3D printing when you need complex, high-performance metal parts in low to medium volumes, especially with internal channels, lattices, or consolidated assemblies. It fits best when geometry drives performance and justifies higher per-part cost versus simpler processes. Use it to shorten lead time on functional prototypes or bridge production before hard tooling.

vs CNC machining

Choose metal 3D printing when the geometry blocks tool access, requires internal passages, or needs aggressive weight reduction with lattices and organic shapes. It is also attractive for consolidating multiple machined parts into one printed assembly, even if you still plan to machine critical interfaces afterward.

vs Casting

Choose metal 3D printing when you need complex internal channels, rapid design changes, or low volume parts that don’t justify tooling. It is also useful for highly optimized or customized geometries where pattern and mold fabrication would be slow or costly.

vs Plastic 3D Printing

Choose metal 3D printing when the part must carry structural loads, endure high temperatures, or handle wear and pressure that plastics cannot. Use it for functional prototypes and end-use parts where mechanical properties and thermal resistance are critical rather than just form and fit.

vs Composites 3D Printing

Choose metal 3D printing when you need higher temperature capability, better fatigue and impact performance, or pressure-containing structures that composites struggle with. It is often better for small, intricate, highly loaded parts where metallic behavior and precision matter more than maximum stiffness-to-weight ratio.

vs Sheet metal fabrication

Choose metal 3D printing when the design requires 3D features, thick sections, or internal passages that cannot be formed from flat stock. It also helps when you want to eliminate welded assemblies and brackets by integrating features into a single monolithic part.

Design Considerations

  • Maintain minimum wall thickness per process and alloy (often 0.020"–0.040") to avoid distortion or incomplete fusion
  • Design self-supporting angles (typically ≥45°) and minimize overhangs to reduce supports, print time, and post-processing cost
  • Add machining stock on critical surfaces and holes that need tight tolerances or good surface finish after printing
  • Use fillets at internal corners and smooth transitions between sections to reduce stress concentrations and improve printability
  • Consolidate assemblies thoughtfully, but leave access for support removal, machining tools, and inspection probes
  • Orient the part to balance support volume, surface quality on critical faces, and build height, then lock that orientation in your RFQ notes