Four Metal 3D Printing Processes & Their Materials: A Comprehensive Guide

Table 1. Metal Powder Bed Fusion Pros and Cons

Pros

Intrinsic support from the powder bed, no supports required

Cons

Some manufacturers offer a limited range of material compositions

Pros

Smooth surfaces direct from the printer

Cons

Requires high-quality, expensive lasers

Pros

20 µm minimum layer thickness, commonly 35–50 µm

Cons

Some systems offer relatively slow build

Pros

Builds more-porous parts

Cons

High residual stresses result from unstable melt pools

Pros

Cons

Printed parts are not equally strong or resilient from all processes; always weaker and more fracture prone than EBM parts

Table 2. Directed Energy Deposition Pros and Cons

Pros

Fast printing speed

Cons

Equipment costs are very high

Pros

Printed parts have high density and strength/resilience

Cons

Support structures cannot be built, so overhangs are not printable, limiting applications

Pros

Can be used for repair of high-quality functional parts

Cons

Relatively low build resolution

Pros

Large build tables available

Cons

Poor surface finish requires post-processing

Pros

Native material properties in parts

Cons

Pros

Allows production of parts with minimal tooling

Cons

Pros

Reduced material waste

Cons

Pros

Can build parts with custom alloy (multi-material range capability)

Cons

Table 3. Metal Filament Extrusion Pros and Cons

Pros

No special build environment – room temp, normal atmosphere

Cons

Difficult post-process to sinter parts

Pros

FFF stresses in printed parts

Cons

Shrinkage makes dimensions in the finished part hard to control

Pros

Wide range of materials on the same machine

Cons

Part accuracy is largely unrelated to X-Y-Z resolution of print

Pros

Lower-cost equipment

Cons

Parts are low density and relatively weak after sintering

Pros

Lower technical skills required in operation

Cons

Pros

Great for prototypes

Cons

Table 4. Material Jetting and Binder Jetting Pros and Cons

Pros

No special build environment—room temp, normal atmosphere

Cons

Two-stage process—powder bed is laid down, then the adhesive is ink-jetted to bond the layer

Pros

No internal stresses in printed parts

Cons

Delicate post-process to sinter parts

Pros

Wide range of materials on the same machine with no alteration in setup

Cons

Dimensional control requires finesse to ensure correct shrinkage

Pros

Lower-cost equipment

Cons

Finished part accuracy is not purely a result of X-Y-Z resolution of print

Pros

Lower technical skills required in operation

Cons

Parts are brittle and vulnerable before sintering

Pros

35 µm minimum layer thickness

Cons

Metal 3D printing is a laser-based technology that fuses metal particles layer by layer. This technology is commonly used for prototyping, production of parts with complex geometries, and end-use parts, as well as for the reduction of metal components in an assembly. Metal 3D printing is supplied with a growing family of materials. This satisfies the needs of diverse industries from jewelry to aerospace, and medical to plastics manufacturing. Some processes and equipment are material-specific and limited in their range, while others are capable of using a range of materials.

To learn more, see our article on 3D printing.

How Do I Select the Best Type of 3D Printing?

Selecting the best type of 3D printing is complex. Below are useful steps to go through when deciding which metal 3D printing processes to choose:

1. Review part requirements. For example, give consideration to the layer resolution, the need for the reproduction of fine detail, as well as the required mechanical properties and cosmetic quality considerations.
2. Choose a material family for the part. 
3. Once the material has been selected, review the available processes that use that material to consider the best one to produce the desired results.
4. Check the availability of resources, including suppliers for the material, time, and costs.

What Are Metal 3D Printing Materials?

There is a long and growing list of metal-type options in metal 3D printing materials. The most common metal types are:

1. Stainless Steel: Generally in 3 alloy groups: 304, 316, and 17-4. These are corrosion-resistant and of high strength when not porous.
2. Tool Steels D2, A2, and H13: Have high strength, are hardenable, wear-resistant, and are applicable for dies and tools.
3. Titanium and Ti64: Materials that are ideal for lightweight parts and have high strength.
4. Aluminum 7075, 4047, 6061, 2319, 4043: These are various lightweight alloys for general, lightweight components.
5. Inconel® 718, 625: These have low corrosion and high-temperature resistance for purposes such as engine parts.
6. Cobalt Chrome: Superalloy for biomedical and aerospace applications.
7. Gold/Silver: Pure metals for jewelry and limited biomedical uses.
8. Niobium, Niobium-Zirconium: These are high-temperature and high–chemical–resistance alloys for aerospace use.
9. Tantalum: Similar to Niobium but with better chemical resistance.
10. Hastelloy® Nickel Chromium: Materials that are tough—temperature-resistant and crack-resistant. Commonly used for turbine and nuclear components.
11. Tungsten and Alloys: Materials with super-high density. Used commonly for radiation shields, collimators, and engine parts.

To learn more, see our guide on the best materials for metal 3D printing.

When Did 3D Metal Printing First Appear?

The earliest practical execution of a metal 3D printer was the EOSINT M250. It was launched in 1994 by ElectroOptical Systems. It combined metal with a lower-temperature alloy, which was fused to couple the primary particles. In 2004, EOS launched the EOSINT M270. It was the first PBF system that used a diode pump 200W laser to melt the metal feedstock. Since then, there has been an exponential increase/improvement in methods, materials, and resolutions.

Summary

Xometry provides a wide range of manufacturing capabilities, including metal 3D printing for all of your prototyping and production needs. Get your instant quote on metal 3D printing and more today.

Copyright and Trademark Notices

1. Inconel® is a registered trademark of Huntington Alloys division of Special Metals Corp., Huntington, WV.
2. Hastelloy® s a registered trademark of Haynes International, Kokomo, Indiana.

Disclaimer

The content appearing on this webpage is for informational purposes only. Xometry makes no representation or warranty of any kind, be it expressed or implied, as to the accuracy, completeness, or validity of the information. Any performance parameters, geometric tolerances, specific design features, quality and types of materials, or processes should not be inferred to represent what will be delivered by third-party suppliers or manufacturers through Xometry’s network. Buyers seeking quotes for parts are responsible for defining the specific requirements for those parts. Please refer to our terms and conditions for more information.

Dean McClements

Dean McClements is a B.Eng Honors graduate in Mechanical Engineering with over two decades of experience in the manufacturing industry. His professional journey includes significant roles at leading companies such as Caterpillar, Autodesk, Collins Aerospace, and Hyster-Yale, where he developed a deep understanding of engineering processes and innovations.

Read more articles by Dean McClements