Electron Beam Melting (EBM)

Electron Beam Melting produces fully dense metal parts in vacuum, ideal for complex titanium and nickel-alloy geometries with integrated lattices and low residual stress.

Overview

Electron Beam Melting (EBM) is a metal powder bed fusion process that uses a focused electron beam in vacuum to melt conductive metal powders layer by layer. It excels with reactive, high-performance alloys like titanium and nickel superalloys, delivering near-wrought mechanical properties and excellent fatigue performance. The vacuum environment minimizes oxidation and contamination, which is critical for aerospace and medical applications.

EBM makes sense when you need complex, organic geometries, internal channels, or lattice structures in high-value metals, and you can accept moderate surface roughness and feature resolution. Build rates are relatively high for thick-walled sections, but minimum feature sizes and thin walls are less refined than laser-based systems. Expect post-machining on critical interfaces, tighter tolerances, or smooth sealing surfaces. Tradeoffs include higher part cost than machining for simple geometries, limited material options compared to other processes, and constraints on minimum wall thickness and fine details.

Common Materials

  • Ti-6Al-4V
  • Pure titanium
  • Inconel 718
  • CoCr alloy
  • Inconel 625

Tolerances

±0.005" to ±0.010" (±0.13 mm to ±0.25 mm) before post-machining

Applications

  • Orthopedic hip and knee implants
  • Spinal cages and porous medical implants
  • Lightweight aerospace brackets and mounts
  • Turbine blades and vanes in nickel alloys
  • High-performance heat exchangers with lattice cores
  • Dental implants and abutments

When to Choose Electron Beam Melting (EBM)

Choose Electron Beam Melting for complex, highly loaded metal parts in titanium or nickel alloys where internal lattices, organic shapes, or porous structures add value. It fits low to medium production volumes of high-value components where vacuum processing, low residual stress, and near-wrought properties justify higher part cost and post-machining.

vs Laser Powder Bed Fusion (DMLS/SLM)

Pick EBM over laser powder bed fusion when printing titanium or nickel alloys that benefit from vacuum processing, lower residual stresses, and thicker sections. EBM handles larger cross-sections with less distortion and allows built-in porous structures for medical implants, at the expense of finer feature detail and surface finish.

vs Binder Jetting (Metal)

Pick EBM over metal binder jetting when you need fully dense, high-strength parts with critical mechanical or fatigue performance straight from the build (plus minimal HIP), not sintered components. EBM suits complex, lower-volume aerospace and medical parts where part integrity and microstructure are more important than maximum throughput or lowest per-part cost.

vs Direct Energy Deposition (DED)

Pick EBM over Direct Energy Deposition when you need better dimensional accuracy, finer features, and more controlled lattice or internal geometries in small-to-medium-sized parts. DED is better for large structures and repair/feature add-ons, while EBM is better for net-shape, detail-rich components built from powder beds.

vs CNC machining

Pick EBM over CNC machining when geometry drives cost—complex internal channels, undercuts, or lattice regions that are impossible or extremely expensive to machine. For simple prismatic or turned parts, machining remains more economical, but EBM shines when design freedom and weight reduction matter more than surface finish out of the machine.

Design Considerations

  • Target minimum wall thickness of 0.8–1.5 mm depending on height and alloy; avoid tall, slender unsupported walls
  • Design overhangs at ≥50–60° to reduce supports; where supports are unavoidable, place them on non-critical, easily accessible surfaces
  • Include powder removal paths (≥3 mm diameter) and avoid blind internal cavities where powder can trap
  • Add machining stock (0.010–0.030" / 0.25–0.75 mm) on critical interfaces, bores, and sealing surfaces for post-machining
  • Use lattice and porous regions with manufacturable strut diameters (typically ≥0.4–0.6 mm) and avoid extremely fine features that exceed beam spot capability
  • Keep part count per build and orientation consistent when requesting quotes, and specify required material properties, HIP, and surface finish up front