Electron Beam Melting (EBM)

Electron Beam Melting (EBM) builds fully dense metal parts by melting powder with an electron beam in vacuum, excelling with titanium alloys and complex lattices.

Overview

Electron Beam Melting (EBM) is a powder bed fusion metal 3D printing process that uses an electron beam to melt metal powder layer-by-layer inside a vacuum chamber. The powder bed is typically preheated to high temperature, which reduces residual stress and supports robust builds of reactive alloys.

Choose EBM for medium-size, high-value parts where internal channels, lattices, and near-net shapes eliminate machining and assembly. It’s common for titanium medical and aerospace hardware that benefits from vacuum processing and good as-built material properties.

Tradeoffs: surface finish is relatively rough and features can look “sintered,” so sealing surfaces and holes usually need machining. Minimum feature sizes are coarser than laser PBF, and dimensional accuracy is moderate; plan on post-process for tight tolerances. Part size is limited by the build envelope, and powder removal from deep cavities must be designed in.

Common Materials

  • Ti-6Al-4V
  • Ti-6Al-4V ELI
  • Inconel 718
  • CoCrMo
  • Commercially pure Titanium

Tolerances

±0.005" to ±0.010"

Applications

  • Acetabular hip cups
  • Spinal fusion cages
  • Titanium lattice orthopedic implants
  • Aerospace titanium brackets
  • Lightweight lattice heat exchangers
  • Custom cranial plates

When to Choose Electron Beam Melting (EBM)

EBM fits low-to-medium volumes where complex internal geometry, lattices, or weight reduction justify additive cost and post-processing. It’s a strong choice for reactive alloys (especially titanium) and parts that benefit from lower residual stress due to hot, vacuum builds. Plan for secondary machining on interfaces, holes, and cosmetic surfaces.

vs Laser Powder Bed Fusion (DMLS/SLM)

Choose EBM when titanium is primary, vacuum processing matters, and lower residual stress/warpage is a priority for thicker, structural geometries. EBM typically gives rougher surfaces and coarser detail than laser PBF, but can be more forgiving on distortion for certain builds and lattice-heavy parts.

vs Binder Jetting (Metal)

Choose EBM when you need near-wrought density and mechanical properties directly from the build with less reliance on sintering shrink control. Binder jetting can be attractive for higher volumes, but EBM is better when accuracy after sintering and achieving consistent high strength are key risks.

vs Direct Energy Deposition (DED)

Choose EBM for intricate shapes, internal channels, and fine lattice structures that DED can’t resolve. DED is strong for large parts and adding features/repairs on existing components, while EBM targets near-net new parts within a powder-bed build envelope.

Design Considerations

  • Add machining stock on all critical interfaces (sealing faces, bearing pads, datum surfaces) and call out post-machining tolerances there
  • Avoid deep blind cavities; add powder escape holes and clean-out paths sized for practical powder removal
  • Hold thin walls and fine details to conservative minimums and keep lattices away from critical datums to reduce variability
  • Orient parts to minimize supports on functional surfaces and provide clear support access for removal
  • Specify critical GD&T only where needed and identify inspection datums that will exist after support removal and finishing
  • Define surface finish requirements by zone; allow as-built on noncritical areas to reduce cost and lead time