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Table of Contents

Metal 3D Printing Capabilities

Direct Metal Laser Sintering (DMLS) / Selective Laser Melting (SLM):

Direct Metal Laser Sintering (DMLS) is an industrial 3D printing method that fabricates fully functional metal prototypes and production components in under 7 days. Various metals can be utilized to create final parts suitable for end-use applications.

High-Performance 3D Printed metal Parts
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Metal 3D printing is frequently employed for:

 

  • Creating prototypes using production-grade materials

  • Manufacturing parts with intricate geometries

  • Producing functional components ready for end-use

  • Minimizing the number of metal parts in an assembly

Precision and Tolerances

ParameterPrecision/Tolerance
Dimensional Accuracy±0.1mm to ±0.2mm (depending on geometry and size)
Layer Thickness20 to 60 microns
Surface Roughness (As-Built)Ra 5-20 microns
Minimum Feature SizeTypically 0.25mm (depending on material)
Wall ThicknessMinimum 0.3-0.4mm (depending on material and part geometry)
Positional Tolerance±0.1mm to ±0.2mm
Hole DiameterMinimum 0.5mm (depending on geometry)
Part Density~99% (depending on material)
Build SizeUp to 250 x 250 x 300 mm (standard)

 

Descriptions:

  • Dimensional Accuracy: Indicates the accuracy range of part dimensions during printing, typically within ±0.1mm to ±0.2mm, depending on geometry and size.
  • Layer Thickness: Refers to the thickness of each layer, usually ranging from 20 to 60 microns. Thinner layers provide finer detail.
  • Surface Roughness (As-Built): The roughness of the printed surface, represented in Ra microns; the lower the number, the smoother the surface.
  • Minimum Feature Size: The smallest detail size that can be clearly defined during printing, typically around 0.25mm, depending on the material.
  • Wall Thickness: The minimum achievable wall thickness in the printed part, usually between 0.3-0.4mm.
  • Positional Tolerance: Indicates the accuracy of part positioning in the X, Y, and Z directions, typically within ±0.1mm to ±0.2mm.
  • Hole Diameter: The minimum diameter of holes that can be produced during printing, typically around 0.5mm, depending on the geometry.
  • Part Density: The density of the part, which is close to 100%, indicating that the printed part is nearly identical to the theoretical material density.
  • Build Size: The maximum build volume that can be achieved, usually up to 250 x 250 x 300 mm, depending on the printing equipment.

 

Metal Powders for 3D Printing:

Electron Beam Melting (EBM)
Ti6Al4V (Grade 5)

  • Description: Ti6Al4V, also known as Grade 5 titanium, is a titanium alloy with high strength, light weight, and excellent biocompatibility. It is the most commonly used titanium alloy in additive manufacturing due to its superior mechanical properties.

  • Applications: Ideal for aerospace components, medical implants, and automotive parts where high strength, low weight, and corrosion resistance are crucial.

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316L

  • Description: 316L is a low-carbon stainless steel known for its excellent corrosion resistance, high toughness, and good weldability. It is particularly resistant to chlorides and acidic environments, making it ideal for use in harsh conditions.

  • Applications: Commonly used in the medical, marine, and chemical processing industries for parts such as surgical instruments, heat exchangers, and marine equipment that require high corrosion resistance and durability.

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Inconel 718

  • Description: Inconel 718 is a nickel-chromium superalloy known for its excellent tensile strength, high creep-rupture strength, and corrosion resistance at high temperatures. It is well-suited for extreme environments.

  • Applications: Commonly used in the aerospace, energy, and automotive industries for parts such as turbine blades, rocket engines, and high-temperature fasteners that must endure extreme conditions.

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Pure Copper (Cu)

  • Description: Pure Copper is known for its excellent thermal and electrical conductivity, making it ideal for applications where heat and electricity transfer are critical. It also offers good corrosion resistance in certain environments.

  • Applications: Widely used in the electronics, automotive, and energy industries for components like heat exchangers, electrical connectors, and induction coils that require high conductivity.

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Comparison Table for Various 3D Printing Metal Materials

MaterialMechanical PropertiesThermal PerformanceCorrosion ResistanceElectrical PropertiesSurface FinishBiocompatibilityDensityPrintabilityCost-Effectiveness
316L Stainless SteelGood strength and ductilityModerate heat resistanceHigh resistance to acids and chloridesGood conductivitySmooth after polishingHigh (used in medical implants)High (8.0 g/cm³)Easy to printModerate
17-4 PH Stainless SteelHigh tensile and yield strengthModerate heat resistanceHigh (better than 316L in most environments)Moderate conductivitySmooth, may need post-processingModerateHigh (7.8 g/cm³)ModerateHigh due to strength
AlSi10Mg (Aluminum Alloy)Good strength-to-weight ratioHigh thermal conductivityModerate resistanceHigh conductivityRequires post-processing for smooth finishLowLow (2.7 g/cm³)Easy to printHigh (cost-effective)
Inconel 718 (Nickel Alloy)Excellent strength at high temperaturesExcellent (up to 705°C)Very high resistance, especially in harsh environmentsLow conductivityRough, requires post-processingLowHigh (8.19 g/cm³)ModerateHigh due to durability
Ti6Al4V (Titanium Alloy)High strength, low weightExcellent (up to 400°C)Very high resistance, especially to saltwaterLow conductivityRequires post-processingVery high (used in medical and aerospace)Low (4.43 g/cm³)Challenging to printHigh due to material cost
Cobalt ChromeHigh strength and wear resistanceHigh temperature resistanceVery high, used in corrosive environmentsLow conductivityVery smooth post-polishingHigh (used in dental and medical)High (8.3 g/cm³)ModerateHigh due to material and processing

 

 

Key Insights:

  • Mechanical Properties: Inconel 718 and 17-4 PH provide exceptional strength, especially under extreme conditions, making them ideal for aerospace and high-performance applications. Ti6Al4V is strong yet lightweight, perfect for aerospace and medical implants.

  • Thermal Performance: Inconel 718 excels in high-temperature environments, maintaining its mechanical integrity up to 705°C. AlSi10Mg offers good thermal conductivity, making it useful for applications requiring heat dissipation.

  • Corrosion Resistance: Titanium alloys (Ti6Al4V) and Inconel 718 stand out for their resistance to harsh environments, including saltwater and chemicals, making them preferred choices for marine and chemical applications.

  • Biocompatibility: Ti6Al4V and Cobalt Chrome are highly biocompatible, widely used in medical implants and dental applications due to their excellent tissue compatibility.

  • Density and Printability: Aluminum (AlSi10Mg) offers a favorable combination of low density and ease of printing, making it cost-effective for lightweight applications. On the other hand, materials like Inconel 718 and Ti6Al4V, while more challenging to print, offer unparalleled performance in demanding conditions.

  • Cost-Effectiveness: Aluminum and 316L stainless steel are generally more cost-effective for large-scale or less demanding applications, whereas Inconel and titanium alloys, while more expensive, provide superior performance in high-stakes environments.

Surface Finish Options

 

CategoryPost-Processing Capabilities
Surface Finishing– 3- and 5-axis milling
– Turning
– Polish (Mirror or Brushed)
– Passivation
– Wire EDM
– Tapping and reaming
Heat Treatments– Stress relief
– NADCAP heat treatment
– Hot isostatic pressing (HIP)
– Solution annealing
– Aging
Mechanical Testing– Tensile
– Rockwell Hardness
Powder Analysis & Material– Traceability
– Chemistry
– Particle size and distribution analysis
Selective Laser Melting (SLM) 3D Printing (1)

How Does Metal 3D Printing Work?

Imagine you’re constructing a detailed building, but instead of using bricks, you’re working with tiny metal particles. Each layer is carefully placed according to a blueprint, with a laser or electron beam acting like the hands of a builder, fusing these particles together layer by layer. This process continues until the “metal building” perfectly takes on the desired shape. This is how metal 3D printing works, allowing you to create highly complex and precise structures, much like assembling a beautiful model with building blocks.

Advantages of 3D Printing Metal Parts Compared to CNC Machining

Complex Geometry

3D printing can produce highly complex geometries that are difficult or impossible to achieve with CNC machining. This includes intricate internal structures, lattice designs, and undercuts without needing additional tooling​​.

Material Efficiency

3D printing is an additive process, meaning material is only used where necessary. This results in less waste compared to the subtractive nature of CNC machining, where excess material is removed​​.

Customization

3D printing allows for easy customization of parts. Each item can be modified without altering the production setup, which is more challenging and costly in CNC machining​​.

Speed for Prototyping

For low-volume or prototype production, 3D printing can be faster as it bypasses the need for specific tooling, leading to shorter lead times compared to CNC machining​​.

Limitations of 3D Printing Metal Parts Compared to CNC Machining

Surface Finish

CNC machining generally offers superior surface finish and tighter tolerances compared to 3D printing, which often requires post-processing to achieve similar results​​.

Material Properties

The mechanical properties of 3D-printed metals may not always match those of machined parts due to differences in material density and internal stresses. CNC machining usually produces more consistent and stronger parts​​.

Size Limitations

CNC machines can work with larger parts compared to most 3D printers, which are often limited by the size of the build chamber​​.

Cost for High-Volume Production

While 3D printing is cost-effective for small runs and prototyping, CNC machining is more economical for high-volume production, especially for simple geometries​​.

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Pricing Structure for Metal 3D Printing Components

Material Pricing
The cost of aluminum alloy powder, such as AlSi10Mg, typically ranges from $50 to $100 per kilogram, depending on the supplier and market conditions​

Design Complexity
Complex designs with intricate details or tight tolerances may require additional supports and more precise printing, which can increase costs due to extended printing time and post-processing requirements​

Printing Duration
The printing time for aluminum parts, especially using techniques like DMLS (Direct Metal Laser Sintering) or SLM (Selective Laser Melting), directly impacts the cost. More complex parts will require longer build times, affecting the overall price​

Post-Processing Techniques
Optional finishing processes, such as heat treatment, machining, and surface polishing, can add to the total cost. These steps are essential for achieving the desired mechanical properties and surface quality​

Support Material and Removal
Aluminum parts often require supports during printing, which need to be carefully removed in post-processing. This process incurs additional labor costs, particularly for complex or detailed parts​

Consider a typical aluminum alloy component with the following specifications:

  • Size: 100mm x 50mm x 10mm
  • Design Complexity: Moderate
  • Surface Treatment: Polished
  • Order Volume: 100 units

Material Pricing

  • Cost of aluminum alloy powder per kilogram: $75
  • Volume per unit: 0.3 kilograms
  • Total material price: 100 units x 0.3 kilograms/unit x $75/kilogram = $2,250

Printing Pricing

  • Time required for printing moderate complexity: 4 hours per unit
  • Rate per printing hour: $80/hour
  • Total printing price: 100 units x 4 hours/unit x $80/hour = $32,000

Post-Processing Cost

  • Cost for heat treatment and machining: $30 per unit
  • Total post-processing price: 100 units x $30/unit = $3,000

Support Removal

  • Estimated labor cost for support removal: $15 per unit
  • Total support removal price: 100 units x $15/unit = $1,500

Additional Expenses

  • Charges for quality assurance and inspection: $400
  • Costs for packaging and delivery: $250

Total price = Material price + Printing price + Post-processing cost + Support removal + Additional expenses
Total price = $2,250 + $32,000 + $3,000 + $1,500 + $650 = $39,400

Price per unit = Total price / Order volume
Price per unit = $39,400 / 100 units = $394/unit

This example provides a general idea of the costs involved in 3D printing aluminum alloy components. Prices may vary based on specific design requirements, processing techniques, and order volumes. For an accurate quote, detailed mechanical drawings and technical specifications should be provided. We will then offer a customized quote tailored to your specific needs.

Bulk Order Incentives and Base Order Requirements

Modo Rapid offers discounts for bulk orders, increasing cost-effectiveness for larger quantities. We accommodate both small and large projects with flexible base order requirements.

3D Printing titanium Components (1)

Production Capacity and Delivery Time

Estimated Delivery Timeframe

At Modo Rapid, we prioritize delivering your orders promptly while ensuring the highest quality standards. Typically, you can expect your order to be delivered within 3 to 7 days, which includes:

  • Order Review and Setup: 1-2 days
  • Material Acquisition: 1-2 days
  • Manufacturing and Machining: 2-3 days
  • Quality Assurance: 1 day
  • Packaging and Dispatch: 1 day

Accommodating Urgent Orders

We understand that some projects require a faster turnaround. If you need your order expedited, please inform us when placing the order. We offer rush processing, though additional costs may apply depending on our workload and the complexity of your project. In many cases, we can adjust our schedule to deliver your order within as little as 3 days.

Our team is committed to meeting your deadlines, even for high-priority tasks. For more details on rush processing or to discuss your specific needs, please reach out to us directly. We are here to work with you to ensure your project stays on track.

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Intellectual Property Protection

At Modo Rapid, we understand that your designs often contain sensitive information, especially in the realm of 3D printing and prototyping. To safeguard your intellectual property, we are fully committed to signing Non-Disclosure Agreements (NDAs) upon request.

Our stringent confidentiality protocols ensure that your data remains secure and protected throughout the manufacturing process. Rest assured, with us, your designs are handled with the utmost care and discretion, allowing you to focus on innovation without concerns about data security.

additive manufacturing services (1)
Rapid Prototype Using 7075 Aluminum
Stainless Steel 316L 3D Printing
Hankook Tire’s Advanced 3D Printing Center

Quality Control and Quality Consistency in 3D Printing

Our Quality Assurance Practices:

Precision Measurement Tools: We use state-of-the-art CMMs (Coordinate Measuring Machines), laser scanners, and precision gauges to ensure every dimension and geometry is accurately captured.

Real-Time Production Monitoring: Our vigilant monitoring during the machining process allows us to immediately identify and correct any deviations, ensuring consistent quality throughout.

Rigorous Material Testing: We conduct exhaustive tests on all materials for chemical composition and mechanical properties, ensuring they meet your precise specifications.

Surface Quality Verification: By employing advanced profilometers and other tools, we make certain that every part adheres to the highest surface quality standards you expect.

Controlled Manufacturing Environment: We maintain strict environmental conditions to reduce any impact of temperature and humidity fluctuations on the precision of our machining.

 

Strategies for Consistent Quality Across Batches:

Standardized Operational Protocols: Each operation follows rigorously defined procedures, promoting uniformity and repeatability across all production runs.

Initial Batch Inspection: We conduct comprehensive first article inspections to confirm that the initial product of each batch meets your requirements before commencing full-scale production.

Statistical Quality Control: We apply statistical process control methods to ensure that our manufacturing processes remain within your required precision limits.

Batch Traceability: Our detailed traceability systems track every material and process step for each batch, enhancing our ability to quickly pinpoint and address any quality concerns.

Thorough Final Assessments and Tests: Before any part leaves our facility, it undergoes a stringent final inspection and functional testing to ensure it meets your exact specifications and quality expectations.

With these rigorous quality control protocols in place, we are dedicated to delivering consistently high-quality parts that support the success and dependability of your projects.

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Maximum and Minimum 3D Printing Part Sizes

Maximum 3D Printed Part Size

  • Direct Metal Laser Sintering (DMLS): Up to 250 x 250 x 300 mm (10″ x 10″ x 12″)​.
  • Binder Jetting: the maximum 3D printed part size typically ranges up to 800 x 500 x 400 mm for metal components, making it ideal for large-scale production compared to other 3D printing methods​

These capabilities allow us to meet the needs of projects requiring expansive size capabilities or meticulous specifications with unmatched precision and efficiency.

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Selective Laser Melting (SLM) 3D Printing (1)
High-Precision Aluminum 3D Printing

Minimum 3D Printed Part Size

 

  • Direct Metal Laser Sintering (DMLS): Small features can be printed with a resolution of 0.2 mm, suitable for intricate metal parts​ 
  • Binder Jetting: the minimum part size can vary but usually has a recommended length of around 50 mm, particularly due to the complexities involved in the post-processing steps like sintering and infiltration
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Aluminum (AlSi10Mg) 3D Printing Technology

Most Popular Questions

Yes, metal 3D printing is quite expensive, with materials like stainless steel 316L costing upwards of $450 per kilogram.

Reducing material usage, minimizing part volume, and eliminating support structures where possible are key to lowering costs.

Yes, support structures are always required due to the high processing temperatures involved in metal 3D printing.

 

  • Standard Grade: Ideal for prototypes and simple end-parts, with strength and density similar to cast parts.
  • Performance Grade: Suited for complex production, offering higher strength and density, preferred for demanding applications.
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Why Choose Us

Precision

Our metal 3D printing services achieve exceptional precision, meeting strict tolerances for even the most complex designs. With advanced technologies like DMLS and SLM, we deliver parts with outstanding detail and accuracy, ensuring your components fit and function perfectly.

Fast Turnaround

With production times ranging from 1-7 days, Modo Rapid quickly delivers high-quality 3D printed parts, allowing you to meet tight project deadlines without sacrificing quality.

24/7 Operations

Our 24/7 operations ensure continuous production and on-time delivery, no matter how tight the deadline. We’re always ready to meet your urgent 3D printing needs.

Seamless Communication

At Modo Rapid, we prioritize effective communication. Our team is readily available via video calls, phone calls, and emails, making collaboration smooth and efficient throughout the 3D printing process.

Consistent Finishing

Our post-processing services, including polishing, bead blasting, and anodizing, deliver consistent, high-quality finishes. We ensure your 3D printed parts are not only functional but also visually appealing.

VIP Shipping Rates

Thanks to our VIP partnerships with leading shipping companies, Modo Rapid offers reduced shipping costs, ensuring your 3D printed parts arrive quickly and affordably, no matter where you are located.

What they say about us

I had very strict dimensional requirements for my part, and Modo Rapid delivered flawlessly. The 3D printed metal part featured clean, precise threading and a finely detailed surface finish. I’m thoroughly impressed with the accuracy and aesthetics.
Harrison Atkinson
Harrison Atkinsontechnical buyer
The stainless steel component I ordered turned out exactly as needed. The surface is smooth and glossy, and the threads are incredibly clean. Modo Rapid nailed every detail. I’ll definitely be returning for future 3D printing projects.
Customer Testimonials
Bethany RogersEngineer
I was concerned that some of the intricate shapes on my part wouldn’t be possible with 3D printing. But when I received the final piece, I was blown away. Every dimension, shape, and thread was executed perfectly. The bead-blasted and anodized finish looks fantastic. Despite being a one-off, the part looks professional and fits perfectly into my assembly.
Samuel Wood
Samuel WoodProject Manager
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