Important facts to consider for additive manufacturing of aluminium, stainless steel and more

In which cases is metal 3D printing worth it?

Additive manufacturing has advantages for metals compared to conventional manufacturing procedures such as turning and milling. Since metal 3D printing is based on a different cost structure, there are a number of facts to consider in order to use the technology to its advantages.

^{This blog post was updated on: 27.01.2023}

Suitable applications

When is metal 3D printing the better option compared to turning/milling?

Metal 3D printing is suitable for various applications:

When lightweight construction is required, i.e. when weight reduction is not possible due to the limitations of turning and milling. Components with complex geometries can be more optimised with 3D printing. Completely new shapes, topology-optimised using lattice structures or curves are created. The metal parts are just as stable as conventionally manufactured parts, but with much less weight. Lightweight parts are used in vehicles and in the aerospace industry, where lower weight and thus fuel reduction play a major role.

Another area of application is heat sinks. With 3D printing, thin and complex cooling structures can be optimally placed and shaped according to the component.

For use in the food industry, where small quantities of specifically adapted parts are often needed to process food according to the mould. The parts are cheaper in small series than injection moulded parts in plastic, as expensive moulds are no longer required. The use of metals such as stainless steel also ensures biocompatibility.

In industrial automation for grippers for robots or holders and the like. In addition to the optimised shape, massive weight savings can be made when using aluminium.

In general, the time needed for manufacturing a part is important. A component from the 3D printer is produced within a short time (if the print file is available) and is available much faster. Therefore parts can be ordered on demand, or design changes and reordering can be made on a regular basis.

What does metal 3D printing cost?

You would probably have the perfect answer as to how much it costs. Unfortunately, this is not possible in general, as there are too many factors driving costs in the additive manufacturing of aluminium and other metals.

The following facts are relevant: If a conventional produced metal component is manufactured 1:1 in 3D printing, the costs are usually higher. This is because metal 3D printers are very expensive to purchase and the material, the powder is expensive too. In addition, a complex process is required for processing. Furthermore it has an impact how much space a component takes up in the installation space of the printer, e.g. for honeycomb structures.

If parts can be designed optmized regarding to their application due to the freedoms in additive manufacturing, the additive technology is worthwhile. The same applies when parts are produced in small quantities or cannot be produced in any other way.

If you would like to check your project, talk to our experts. We will be happy to evaluate the perfect solution together with you. There is a choice of SLM or FDM technologies, FDM is cheaper in most cases.

Are there other options or subsitutes to metal 3D printing?

There are plastics that have proven themselves in practice. These include composite materials that are reinforced with carbon fibres and thus withstand high loads. The materials are known from applications in aviation or motor sports. You can identify suitable applications based on the properties:

High load
Stiffness
Heat resistance
Special properties such as flame retardant or chemical resistant

If this is the case, these materials are a real alternative to metals and should be tested:

Onyx carbon fibre reinforced (FDM technology)
Onyx FR flame retardant (FDM technology)
DuraForm® HST fibre-reinforced (SLS technology)

Technical properties of 3D printing metals

The following metals are currently available at Jellypipe:

Aluminum
Stainless steel
Corrosion resistant tool steel (Corrax)
Martensian nickel steel
Inconel (nickel-chromium-iron-molybdenum alloy)
Copper
Titanium

^{Please note that the values in the tables refer to the unprocessed material. If in practice a material is pushed to the limits of the given values, the component itself should be tested. If you have any questions, please do not hesitate to contact us.}

Table Part I/II

	Aluminum (AlSi10Mg)	Inconel 625 (IN625)	Inconel 718 (IN618)	Copper (CuCr1Zr)	Titanium (TiAI6V4)
Technology	SLM	SLM	SLM	SLM	SLM
Density [g/cm3]	2.3	8.44	8.2	8.9	4.5
Tensile strength [MPa]	250	938	1350	340	900
E-modulus [Gpa]	70	170	180	110	110
Elongation at break [%]	1	30	17	25	10
Properties	High strength and dynamic load capacity, light weight,	High strength, high heat resistance, high corrosion resistance, and high oxidation resistance.	High strength, high heat resistance (700°), high corrosion resistance and high oxidation resistance.	High electrical and thermal conductivity and good finishing capabilities.	Titanium alloy with high strength. Corrosion resistant, light weight.

Table Part II/II

	Stainless steel 1.4404	Stainless steel 1.4542	Corrosion resistant tool steel (Corrax)	Martensian nickel steel 1.2709
Technology	SLM	SLM	SLM	SLM
Density [g/cm3]	7.9	7.8	7.7	8
Tensile strength [MPa]	510	900	1100	1050
E-modulus [Gpa]	180	140	170	160
Elongation at break [%]	45	25		11
Certifications			Food
Properties	Good corrosion resistance, high conductivity	High corrosion resistance, sterilizable, high strength, high ductility	High corrosion resistance, high strength, food certified, good post-processing capabilities	Excellent tensile strength & toughness, Especially low warpage

Download this material-list here:

How large parts can be printed?

The installation spaces of the printers in the SLM have an installation space of 300 x 300 x 250 mm. If you need larger parts, please create an individual request on the platform. The minimum wall thickness of the parts must be at least 1 mm for both additive manufacturing technologies.