FAQ
What metal 3D printing processes are there?
In metal 3D printing, there are a variety of different additive manufacturing processes for component production, each with their own advantages and disadvantages, for example in terms of costs, component dimensions, material selection and component complexity.
LPBF (Laser Powder Bed Fusion, PBF-LB) or SLM® (Selective Laser Melting)
- With a market share of over 90%, the LPBF process is most frequently used for the production of functional metal 3D printed components. It is therefore also the preferred process at Rosswag for the production of metal components for industrial applications. One or more lasers are used as an energy source for localized melting of the metal powder in the powder bed.
- Other frequently used process names for the LPBF process are DMLS (Direct Metal Laser Sintering), LaserCUSING, ALM (Additive Layer Manufacturing), LMF (Laser Metal Fusion), LBM (Laser Beam Melting).
The component to be manufactured is built up layer by layer from metal powder using laser micro-welding processes. This creates the physically dense component close to the final contour in the powder bed. Unmelted metal powder can largely be reused after the construction process.
Thanks to the layered structure of metal 3D printing, even highly complex geometries can be created without additional effort. Function-optimized geometries include, for example, near-contour, internal channel structures, which can be used to achieve a significantly better cooling or heating effect. In addition, there are also possibilities for combining the functions of complex assemblies in one component. This design, known as integral construction, reduces the amount of post-processing and assembly work required, as individual components can be combined with each other during production. Lightweight construction applications also benefit from metal 3D printing, as topology optimization, cavities or honeycomb structures in unloaded geometry areas can achieve high weight savings with good rigidity.
EBM (Electron Beam Melting, PBF-EB)
- A process comparable to LPBF with electron beams as the energy source used and usually higher process temperatures.
DED (Direct Energy Deposition)
- In the DED process, powdered or wire-shaped starting material is fed via a nozzle and melted using a laser, electron beam or electric arc. This also enables multi-axis deposition processes on large components. Depending on the combination of processes used, the process is referred to as Laser Metal Deposition (LMD), Electron Beam Additive Manufacturing (EBAM), Wire Arc Additive Manufacturing (WAAM) or Wire Laser Additive Manufacturing (WLAM).
Metal Binder Jetting
- Also known from the plastics industry, metal binder jetting involves selectively bonding metal powder in a powder bed using a binder. The resulting green part is then freed from the binder using thermal processes and sintered to form a dense component.
Fused deposition modeling (FDM) or fused filament fabrication (FFF)
- As with plastic 3D printing for home use, a filament is melted and deposited in layers. However, the filament contains metal powder particles, which are then bonded by debinding and sintering to form a dense metal component.
In which areas is SLM used?
Metal 3D printing processes such as selective laser melting (SLM) have a wide range of applications and offer numerous advantages in the manufacturing industry. This technology enables the production of highly complex components from different metal powders. The choice of powders, including aluminum, stainless steel, titanium and Inconel, allows companies to use precise materials depending on strength, heat treatment and other property requirements. The use of metal printing is particularly important in mechanical engineering and the aerospace industry, as it enables components with specific properties, such as low weight and high strength, to be manufactured.
Metal 3D printing processes are not only suitable for the production of prototypes, but also for the production of small series. The flexibility in adapting the process parameters allows companies to realize different alloys and microstructures. In addition, metal printing enables high precision in the production of tool steels, which are used in industry for milling and other machining processes. Companies can thus efficiently cover the entire process chain from digital modeling to the finished component, resulting in shorter development times and cost-efficient production.