3D Printing Metal Powder

All You Need To Know About 3D Printing Metal Powder Suppliers

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3D printing metal powder is revolutionizing manufacturing across industries like aerospace, automotive, medical, and more. This advanced additive manufacturing technique builds metal parts layer-by-layer from powdered metal alloys using lasers or electron beams.

Compared to traditional metal fabrication processes, 3D printing with metal powder offers increased design freedom, faster prototyping, reduced waste, and lower costs for short runs and custom parts. However, powder metallurgy poses unique requirements on particle size, shape, composition, and other properties.

Metal Powder Manufacturing Methods

Metal powders can be produced in different ways. The main manufacturing methods include:

Gas Atomization

Molten metal alloy is atomized into fine droplets using an inert gas jet. The droplets rapidly solidify into spherical powder particles. Gas atomized powders have excellent flowability and packing density desired for 3D printing.

Plasma Atomization

Similar to gas atomization, but uses plasma torches to produce higher temperatures for superior powder characteristics. Allows a broader range of alloys.

Mechanical Alloying

Powder produced by high energy ball milling of metal powders and alloying elements. Powders have irregular shape but allow wider range of compositions.

Electrolysis

Metal is electrolytically dissolved from an anode and deposited onto a cathode in powder form.

Chemical Reduction

Metal oxides or salts are chemically reduced using hydrogen or carbon to produce metal powders.

Metal Dehydration

Hydrated metal salts heated to remove water and produce metal or metal oxide powders.

Consolidation & Spheroidization

Irregular powders milled, pressed and spheroidized into spherical shape. Enables recycled scrap powder use.

Gas atomization is most commonly used for additive manufacturing today, producing high quality spherical powders for excellent packing density and powder bed surface quality.

3D Printing Metal Powder Compositions

Many alloys are used for metal powder bed 3D printing. Common alloys include:

Alloy Type	Examples
Nickel Superalloys	Inconel 625, 718, In625, N06625, In718
Cobalt Chrome	CoCrMo, Co28Cr6Mo
Titanium Alloys	Ti-6Al-4V, Ti64, Ti6242, TiAl6V4
Tool Steels	H13, Maraging Steel, Stainless Steels
Aluminum Alloys	AlSi10Mg, AlSi7Mg0.6
Copper Alloys	CuSn10, CuAl10Ni5Fe4

Nickel superalloys offer the best high temperature strength and are extensively used in aerospace engines and components.

Titanium alloys like Ti64 are known for strength, low weight and biocompatibility making them popular for medical implants and aerospace.

Cobalt chrome is primarily used for dental implants and crowns due to biocompatibility and corrosion resistance.

Tool steels and stainless steels are used for injection molds, tooling and high-strength mechanical parts across industries.

Aluminum and copper alloys are newer for metal 3D printing, enabling more applications in automotive, heat exchangers and conformal cooling channels.

Metal Alloy Powder Particle Size Range

Description	Size Range
Extra Fine	15 – 25 microns
Fine	25 – 45 microns
Medium	45 – 90 microns
Coarse	90 -150 microns

Finer powders around 20-45 microns are preferred for complex geometries and smooth surface finish. Coarser powders above 45 microns allow faster build speeds but poorer resolution. Optimal size ranges depend on the 3D printer model and capabilities.

3D Printing Metal Powder Properties

Metal powders must meet strict specifications for 3D printing suitability:

Property	Description	Desired Values
Particle Size Distribution	Range of powder particle diameters	Tight distribution around 20-45 μm typical
Particle Shape	Powder morphology – spherical, irregular etc	Highly spherical particles
Flowability	Ability of powder to flow during 3D printing	Excellent flow like water
Apparent Density	Powder packing density	>4.0 g/cc
Tap Density	Maximum packing density after vibration	>4.5 g/cc
Oxygen Content	Oxygen absorbed during manufacturing	<400 ppm
Nitrogen Content	Nitrogen absorbed during manufacturing	<100 ppm

Spherical particle shape allows smooth powder spreading during 3D printing. Chemical purity and low oxygen content reduce defects like porosity and cracking.

Powders must also meet composition standards like ASTM B348 Grade 5 for titanium alloys and AMS 5659 for nickel superalloys.

3D Printing Metal Powder Applications

3D printing with metals allows fabrication of end-use parts across diverse industries. Some major application areas are:

Industry	Applications
Aerospace	Turbine blades, structural frames, engine components
Automotive	Custom prototypes, specialized tools
Medical	Dental crowns, implants, surgical instruments
General manufacturing	Jigs, fixtures, end-use parts
Jewelry	Complex geometries, customized designs

Metal powder-based 3D printing enables production of lightweight, high-strength parts with enhanced thermal properties suitable for harsh operating conditions seen in aerospace engines and turbine systems. It also allows creation of customized medical implants specifically matched to an individual patient’s anatomy.

3D Printing Metal Powder Suppliers and Pricing

There are several major global suppliers that manufacture and distribute metal powder for 3D printing processes. The table below highlights some leading companies and approximate powder pricing:

Company	Key Materials	Typical Pricing Range
AP&C	Titanium, nickel, cobalt alloys	$50 – $220 per kg
Sandvik	Stainless steel, cobalt-chrome, nickel alloys	$50 – $250 per kg
Met3DP	Titanium, aluminum, stainless steel	$30 – $150 per kg
Carpenter Technology	Stainless steels, cobalt alloys, titanium	$100 – $500 per kg
LPW Technology	Stainless steel, aluminum, titanium, Inconel	$50 – $150 per kg

Pricing varies based on composition, quality level, particle size distribution, density specifications, and purchase volume. Ready-to-print powders customized for individual 3D printer models may carry a premium.

Metal Powder 3D Printing vs Traditional Methods

Metal 3D Printing	Traditional Fabrication
Additive process builds up parts layer-by-layer	Subtractive machining methods remove material
No part-specific tooling needed	Significant tooling costs for casting, machining
Design freedom for complex geometries	Design restrictions from tool accessibility
Rapid prototypes in days	Months for prototype tooling
Cost-effective short runs	High volumes needed for cost-benefit
Material waste only from supports	High scrap rates from machining
Consolidated assemblies	Multi-step manufacturing and assembly
Dense, functional metal parts	Additional post-processing often needed

Metal 3D printing enables innovative designs, faster turnaround, and economic low volume production. It complements rather than replaces conventional manufacturing which remains more suited for high volumes.

Wholesale Price: $20/Kg-$500/Kg

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FAQ About 3D Printing Metal Powder

How can I contact Metal3DP customer service?

We provide 24/7 customer support. You can find our contact details on the Contact Us page, including phone, email, and online chat.

What metal powder materials does Metal3DP offer?

We offer various high-quality metal powders including stainless steel, high-temperature alloys, suitable for processes like laser and electron beam powder bed fusion.

How does Metal3DP ensure the quality of 3D printing metal powder?

With extensive metal additive manufacturing expertise, we employ advanced processes and stringent quality control to ensure the mechanical properties and surface quality of parts.

In which industries are Metal3DP's 3D printing devices applied?

Our devices have a wide range of applications in industries like aerospace, medical, automotive, and more, providing solutions for high-performance metal components in manufacturing.

Does Metal3DP offer custom alloy options?

Yes, we provide custom alloy services to meet specific material requirements from clients.

What are the advantages of Metal3DP's SEBM systems?

Our SEBM systems excel in producing complex metal parts with exceptional mechanical properties. Key features include industry-leading build volume, precision, and reliability.

Can I find application cases on the Metal3DP website?

Yes, our website showcases a wide range of application cases demonstrating successful implementations of Metal3DP technology across various industries.

How can I start collaborating with Metal3DP?

Get in touch with us, and our team will provide you with tailored solutions and collaboration plans based on your needs.

What is the turnaround time for Metal3DP's custom services?

The turnaround time for custom services varies depending on project complexity. We will provide accurate delivery times based on your requirements.

What 3D printing technologies does Metal3DP offer?

We specialize in Selective Laser Sintering (SLS), Selective Laser Melting (SLM), and Selective Electron Beam Melting (SEBM) among other 3D printing technologies.

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