What Can You Do With Metal 3D Printing?
(benefits and uses)

Metal 3D printing technologies like selective laser melting (SLM) and direct metal laser sintering (DMLS) offers unparalleled design freedom and unique advantages for producing complex, fully functional metal prototypes or end-use components that may be impossible to produce via traditional metal part fabrication methods.

Main Benefits of Metal 3D Printing

In recent years, metal 3D printing, also known as metal additive manufacturing (metal AM), has gained increasing popularity among many sectors, and for good reason. Here are some of the main benefits of the process:

1. Reduction in Lead Times: Unlike CNC machining and moulding processes which requires some amount of time and effort to go into mould-making and fixtures, metal 3D printing is a ‘toolless’ process. Its ability to produce parts directly from digital designs, enable it to deliver parts faster, shortening lead times from weeks to days and facilitating faster iteration.
2. New Approach to Design: Metal AM technologies allow for the production of unique and complex structures which is extremely beneficial to industrial designers. Traditionally, some elements which can not be casted need to be added to the element in post-production, which can increase the time and effort needed to manufacture a desired shape. However, with 3D printing, complexity of the part does not necessarily generate additional costs.
3. Innovative Material Options: Advanced materials like nickel-based superalloy are difficult to CNC machines due to their complex properties and behaviors. Metal AM enables the precise control and layer-by-layer deposition of such materials, overcoming the limitations of conventional machining methods.

What Challenges Does Metal AM Solve?

Parts on Demand: Additive manufacturing enables companies to print replacement metal parts as onsite and on demand, eliminating the need for large inventories of pre-fabricated parts. This flexibility reduces warehousing costs and minimizes the risk of inventory obsolescence. 

Simplified Assemblies: Metal 3D printing enables the creation of complex parts with integrated features, reducing the need for multiple components and assembly steps. By consolidating parts into single structures, it grants more geometric freedom and often eliminates the need for post-production assembly.

Optimized Features: The design space for additive manufacturing is far different from traditional manufacturing processes, so you can consider how much material you’re adding to your part, rather than what you’re taking away. Save weight on critical components by adding material only where it is needed to make your part perform.

Innovate With Advanced Metals: Metal additive manufacturing provides opportunities for engineers and researchers to work with advanced materials that may be difficult to machine using CNC. This allows for the development of novel materials with enhanced properties and performance characteristics.

What Can You Do with Metal 3D Printing?

To give you a better idea of what you can do with metal 3D printing, we will take a look at examples of how the process is being applied across various industries to improve manufacturing efficiency, optimize product design, and enhance part performance.

Aerospace: Metal 3D printing provides a way to create complex designs and produce lightweight, yet strong structures. These components include turbine blades, fuel nozzles, brackets, and structural parts. Additive manufacturing allows for performance enhancement, customization and weight reduction in aerospace applications.

Medical Implants: Industrial metal printing enables the production of patient-specific implants tailored to individual anatomies. This includes orthopedic implants such as hip and knee replacements, cranial implants, and dental implants. AM allows for complex geometries and porous structures that promote osseointegration and reduce stress shielding.

Automotive: Metal 3D printing is used for rapid prototyping, tooling, lightweight components and the production of aftermarket parts – especially those that were once cast. One of the most unique benefits the process offers in the automotive industry is the amalgamation of multi-part assemblies into one single piece, reducing assembly time and improving performance.

Robotics: Metal printing allows for the fabrication of sensor housings, enclosures, grippers and mounting brackets with intricate designs and integrated features. It also enables the integration of multiple functionalities into a single component.

Oil and Gas: Metal 3D printing is employed for manufacturing components used in drilling equipment, valves, pumps, and sensors. It allows for the production of  corrosion-resistant superalloys and high-strength parts tailored for use in the often-challenging environments in oil and gas extraction and processing. 

Jewelry: Metal AM plays a growing role in the jewelry industry. It is a valuable manufacturing technique for creating customized and intricate jewelry designs, enabling jewelry designers to craft complex geometries and personalized pieces that are not feasible with traditional manufacturing methods.

Disadvantages of Metal AM to Keep in Mind

Although metal 3D printing has proven to be a game-changing technology for industrial designers and engineers in various sectors, it is still in the early stages of development. When considering the process, below are three disadvantages to consider.

• Limited Build Size: Metal 3D printing technologies typically have smaller build volumes compared to other manufacturing methods, as precise manufacturing conditions and process control are required.
• Limited Material Selection: While there is a growing variety of metal powders available for 3D printing, the selection is still relatively limited compared to traditional manufacturing methods.
• High Initial Investment: Metal printers like SLM are much more expensive to own than plastic 3D printers. The costs associated with materials and post-processing equipment can further contribute to the initial investment required for metal additive manufacturing.

Metal 3D Printing Services With HLH Rapid

Looking to produce custom metal 3D printed parts? Contact the HLH team to leverage decades of vast aluminium and stainless steel 3D printing expertise. Simply submit your CAD designs and project details via our site contact form, and our team will get back to you with a quote within 24 hours.