Table of contents

What is the service process?

What types of aluminum are available?

Technical data sheets for aluminum

What are the advantages of 3D printing aluminum compared to conventional manufacturing?

What design principles should be considered when 3D printing with aluminum?

What layer thickness is typically used in aluminum 3D printing?

What tolerances are possible?

What post-processing options are available for aluminum?

What should be considered when ordering a 3D print?

Is small-batch production using 3D printing worthwhile?

How much does 3D printing in aluminum cost?

How robust are metal parts made using 3D printing?

Advantages of prototypes in 3D printing

What processes are there in metal 3D printing?

What is the service process?

To receive a quote for 3D printing, please send us your 3D file in STEP, STL, or a similar format, along with information about the desired material and quantity, via email . For further questions about the process, please contact us to discuss specific requirements and customize the workflow. If you know exactly which type of aluminum you need, you can use our online price calculator .

What types of aluminum are available?

AlSi10Mg 3.2382

AlSi7Mg0.6 3.2384

AlZrFe AA8A61.50

AlSi9Cu3 3.2163

What are the advantages of 3D printing aluminum compared to conventional manufacturing?

It allows for the creation of more complex geometries, offers weight savings through topology optimization, and reduces material waste. Especially for small production runs or prototypes, the process is more cost-effective than casting or milling. 3D printing makes it possible to manufacture complex geometries that would be difficult or even impossible to produce using conventional methods.

What design principles should be considered when 3D printing with aluminum?

Avoid thin walls, tight tolerances, and unnecessary support structures in your designs. Careful planning to minimize rework and material waste is crucial.

The recommended minimum wall thickness is approximately 0.8 mm. For more stable constructions, greater wall thicknesses are advisable, depending on the load requirements of the component.

What layer thickness is typically used in aluminum 3D printing?

The layer thickness is typically 30–70 micrometers, which allows for high precision in detail representation.

Is it possible to manufacture moving parts from aluminum using 3D printing?

In 3D printing, moving parts can be created in a single print run. It is important to allow for a minimum amount of play between the components to prevent fusing. It is also recommended to fix the joints during printing, for example, using temporary connections in the design. Another proven method is to design the part so that it is securely fixed to the print bed to prevent unwanted movement during the printing process. Otherwise, excessive pressure can lead to unwanted material contact or even fusing with the aluminum.

What tolerances are possible?

Tolerances: Individual production ± 0.4% ±0.25mm

Tolerances: Series production ± 0.3% ±0.15mm

What post-processing options are available for aluminum?

Sandblasting

Sandblasting with particles ensures a uniform surface. Different blasting media can affect the surface in different ways.

Drum grinding

During drum grinding, the surface is smoothed, partially lightly polished, and the edges are rounded to give the component a smooth surface.

polishing

Polishing aluminum brings the surface to a high gloss, making it mirror-smooth. This step is useful when a particularly high gloss is crucial.

CNC

3D printing is not always precise. For specific areas, subsequent machining using CNC can be performed. The combination of 3D printing and subsequent CNC machining offers both design freedom and precision in terms of fit.

Coating

Surface coatings allow certain properties to be added through substances that are not possible with the base material alone, such as chemical resistance, surface adhesion, or wear resistance.

Heat treatment

Subsequent annealing of components can increase their hardness, electrical conductivity, or strength. Each material offers specific possibilities for improving its properties.

What should be considered when ordering a 3D print?

Threads: In general, threads should be avoided in 3D printing, as the end result is often rough and functionality is not always guaranteed. An example would be to first print a 3 mm hole for an M4 thread, then drill it with a 3.3 mm drill bit, and finally tap the M4 thread conventionally.

Drilling: With 3D printed metal parts, it is not always guaranteed that holes will be perfectly round due to the printing direction and arrangement; they can be oval or irregularly shaped. To achieve precise results, holes should be printed 0.2–0.5 mm smaller than the final dimension and then drilled to the desired size.

Tolerance: 3D service providers receive 3D models where tolerances can vary, requiring either over- or under-tolerance. To minimize these deviations, it is advisable to design for the middle ground. A carefully created 3D file is therefore crucial for achieving precise and accurate results.

Curves: As with conventional manufacturing processes, curves and radii should always be incorporated into 3D printing to minimize stress. In 3D printing, the number of radii is actually less critical, as it is easier to produce complex shapes. This contrasts with conventional manufacturing processes, where integrating curves involves more time and tooling costs.

Functional dimension: If a particularly smooth surface or precise curves are required to fulfill a specific function, such as a running surface or bearing guide, it is advisable to include a tolerance in the design. This allows the desired accuracy to be achieved through subsequent machining processes. With 3D printing, the surface is typically rough, and the accuracy can be as low as 0.3 mm.

Is small-batch production using 3D printing worthwhile?

Yes, 3D printing can certainly be useful in small-batch production, but this depends on various factors. 3D printing offers advantages for certain applications. For example, complex geometric shapes that are difficult or expensive to produce using conventional manufacturing methods can be realized relatively easily with 3D printing. Furthermore, 3D printing allows for a high degree of design freedom and the mass production of customized products. However, there are also limitations to 3D printing in mass production. Production speed is generally slower than with traditional manufacturing methods, which can lead to longer production times for large quantities. Additionally, material costs for 3D printing can be higher than with other manufacturing techniques. Therefore, it is important for companies to carefully evaluate their specific requirements, costs, and goals to determine whether 3D printing is a viable option for their mass production.

How much does 3D printing in aluminum cost?

The cost of metal 3D printing varies depending on the material used, such as aluminum or stainless steel, and the volume of the desired object. Generally, the cost ranges from approximately €5 to €10 per cubic centimeter (cm³). We also offer an online price calculator where you can upload your file, select the desired material and any post-processing requirements to receive a preliminary cost estimate.

How robust are metal parts made using 3D printing?

3D-printed metals can achieve the same stability as traditionally manufactured parts, depending on the type of aluminum and the printing process. With suitable metals and optimized printing parameters, they achieve high strength and stability.

Advantages of prototypes in 3D printing

A 3D-printed prototype offers the advantage of fast and cost-effective production. Unlike traditional manufacturing methods, which often require expensive tools or molds, 3D printing allows for rapid iteration and adaptation of the design. This enables companies to test the product early on and gather feedback from potential customers or stakeholders. Prototypes can be produced using various materials via 3D printing, eliminating the need to search for different processes and manufacturers.

What processes are there in metal 3D printing?

Here are introductions to the various commonly used metal 3D printing processes. I am currently aware of 12 processes .

Selective laser melting (SLM):

• In the SLM process, metal powder is applied layer by layer and selectively fused using a high-intensity laser. This creates the desired three-dimensional workpiece. Here's a video on YouTube showing how it works.

Electron beam melting (EBM):

• In the EBM process, metal powder is fused with a focused electron beam. This enables the precise manufacturing of complex metal parts. Here's a video on YouTube showing how it works.

Selective electron beam melting (SEBM):

• Similar to EBM, but the melting is selective using the electron beam. This method allows for precise control over the melting process. Here's a video on YouTube. how it works.

Direct Metal Laser Sintering (DMLS):

• In the DMLS process, metal powder is fused layer by layer using a laser. This process is suitable for the production of precise and complex metallic components. Here is a video on YouTube. how it works.

Metal Binder Jetting ( MBJ ) :

• In MBJ (Metal Metal Juicing), metal powder is bonded layer by layer using a binder and then transformed into a solid metal part through heat treatment. Here's a video on YouTube. how it works.

Laser Metal Deposition (LMD):

• Laser metal deposition (LMD) uses a laser beam to apply and fuse layers of metal powder. This allows for the repair of components or the addition of material. Here's a video on YouTube. how it works.

Direct Metal Printing (DMP):

• DMP is a 3D printing process in which metal parts are produced by melting metal powder layer by layer. A laser or electron beam is used to melt the powder and create precise metal components. Here's a video on YouTube. how it works.

Laser Powder Bed Fusion (LPBF):

• LPBF is a high-precision additive manufacturing process in which a focused laser fuses metal particles layer by layer to create complex and customized metal components. This process enables the production of parts with high accuracy and quality. Here is a video on YouTube that illustrates the process.

Direct Energy Deposition (DED):

• DED is a manufacturing process in which metallic materials are built up layer by layer by directly depositing molten wire or powder using a focused energy beam. This method enables the production of large-format components, repair operations, and the integration of various materials. Here is a video on YouTube that illustrates the process.

MoldJet :

• Tritone's MoldJet process is a powder-free 3D printing technology that enables the large-scale, high-speed industrial production of metal and ceramic parts. Here is a video on YouTube that illustrates the process.

Metal Fused Filament Fabrication (FFF):

• In the metal FFF process, the metal filament is first melted and applied layer by layer. This is followed by the debinding process, in which organic components are removed, and then by sintering, in which the metal parts are densified and strengthened. Here is a video on YouTube that illustrates the process.

Wire Arc Additive Manufacturing (WAAM):

• WAAM is a manufacturing process in which metal parts are produced by depositing molten wire layer by layer using arc radiation. This method enables the efficient production of large components with high layer thicknesses, thus saving time and costs. Here is a video on YouTube that illustrates the process.

We offer you the complete package for your 3D printing in aluminum.

3D printing with aluminum offers significant advantages, from its fundamental material properties to its flexible shaping capabilities. If you want to realize your aluminum models as easily as possible, you can rely on us. We offer a complete package for your aluminum 3D printing needs. We support you from the initial design phase and guide you through to successful model production. We rely on the perfect combination of modern technologies, expertise, and a commitment to service.

We produce individual pieces as well as small series using 3D printing with aluminum.

When it comes to 3D printing with aluminum, we tailor our services precisely to your wishes and specifications. This makes us the right partner for you when it comes to producing individual pieces, but we also provide expert and reliable support for small production runs. We can utilize various 3D printing processes to optimally realize your requirements. We would be happy to advise you on the selection process to find the best solution for your needs.

Benefit from low costs and fast turnaround times with 3D printing in aluminum.

With 3D printing in aluminum, you have access to a modern and future-oriented technology that offers a wide range of possibilities. Compared to traditional manufacturing methods, it promises several advantages, particularly in terms of cost and time. The costs associated with 3D printing in aluminum for the production of prototypes and small series are significantly lower. This makes it easier for you as a founder or entrepreneur to realize new product ideas. Furthermore, 3D printing is faster than most traditional manufacturing processes. Would you like a consultation about 3D printing in aluminum? Then contact our team now!