May 27, 2019

3D Metal Printing from A to Z

Check out our infographic detailing the intricate ins and outs of 3D metal printing

36% of companies globally used metal materials for 3D printing in 2018
The global market for 3D printing metals will reach a value of $12 billion by the year 2028

3D metal printing is an additive technology.

Materials are slowly added in very thin layers so dimensions of the final product are precise down to the fraction of a millimeter.

Complex shapes with precision: Assembly parts can be precise and streamlined compared to other manufacturing methods that result in rougher products that need more finishing steps.
Strong finish: Yields one piece with no weak spots due to welds or joints.
Lightweight: Minute pieces of metal translate to very sleek, low-weight final products.
Little to no waste: Metal powder can be treated and used again.
Productive: Up to 50x more productive than traditional manufacturing.
- Faster
- Requires less manpower
- Easy to change designs on the fly

There are two main forms of 3D metal printing: Selective Laser Melting and Direct Metal Laser Sintering.
Both use lasers that scan and melt metal particles, bonding them together according to a preset design.

Fully melts each layer of metal powder to create denser, stronger materials
Can only be used with certain metals like steel, titanium, cobalt chrome, and aluminum

HP® has partnered with GKN Powder Metallurgy® and Parmatech® to create the HP Metal Jet 3D printer.

Computer-Assisted Design (CAD) software is used to create a 3D design.
3D metal printer requires spliced horizontal design rendered on a horizontal plane.

3D metal printer gets instructions from the computer.
Metal powder is spread on the print bed to begin the build.
Print agent is deposited on powder at specific locations, shaping out the geometry of the final product.
Liquid components of print binding agents evaporate.
The print bed retracts, the next layer is printed, and the process repeats until the build is finished.

Printed parts are heated to remove final liquid component of the binding agents and to cure the polymers.

The product is decaked to remove extra material residue before sintering.

The powder material is compacted with heat.

The build undergoes machining and polishing.

Prints materials up to 60% lighter in weight compared to traditional production methods
Eliminates unnecessary waste: extra material can be reclaimed from the printing chamber and recycled
Energy savings for cars and other forms of transport such as the aviation industry
- Less fuel is needed to move a lighter, 3D-metal printed structure
3D-printed metal parts can save Boeing up to $3 million per plane in construction costs
Cars built with 3D metal parts like the Urbee capable of getting impressive mileage: 290 miles per gallon
3D printing has the potential to reduce CO2 emissions by 130.5 to 525.5 Mt by 2025