Metal 3D Printing - From Idea to Realisation

Understanding the Benefits & Processes of Metal 3D Printing

INTRODuCTION

Why CHoose Metal 3d Printing

Metal 3D Printing has become quite popular over the years. it has a diverse array of applications in many different industries.

Manufacturing difficult-to-machine materials such as Tools Steels, Inconel & Copper.
Efficient means of manufacturing - less cost, less waste, and faster fabrication time.
Easier to work with intricate designs, custom internal passageways and holes with long aspect ratios, closed cell infills, or lightweighting is free, as opposed to extracting materials in more traditional methods.

Benefits of Metal 3D Printing

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Reduced production time

To begin with, the most well-known benefit of additive manufacturing is a speedier transition from the design stage to final part production. The majority of the time is saved as a result of the instrumentation. After the object has been 3D printed, no special equipment or machining devices are usually necessary to process it. The operator just needs to delete elements formed during the printing process, such as support structures. This allows for a substantial reduction in post-processing time. To modify the shape of the item, there is no need to tool it with milling or turning. Machining, which was formerly required to produce holes or add other connecting pieces, is no longer required. As a result of 3D printing metal parts, lead times are reduced to days rather than weeks. Injection moulding may be a cost-effective way to produce huge quantities of the same elements. However, first the moulds must be made, and then the manufacturing line's pace, as well as the entire plant, must be improved. As a result, the initial part could arrive in 15 to 60 days, whereas with 3D printing, the lead time could be as short as 2 or 3 days.

Less Overhead Costs & Costs Per Unit

Another benefit of using additive manufacturing to produce metal is the reduction in material waste. Raw material is added and created layer by layer in metal 3D printing, rather than being subtracted or carved out of a bulk solid figure. As a result, the material is only used where it is required, lowering the cost of the primary material used to make one component. As a result, 3D printing is a resource-saving technology. Furthermore, pieces that have been modified for 3D printing might achieve a final mass of 14 times that of the prior version. It could be useful in the automobile and aerospace industries.

No Boundaries to Complexity

When it comes to metal parts, 3D printing technologies enable the creation of one-of-a-kind and intricate structures. Some elements that cannot be casted must traditionally be added to the element in post-production. Adding holes and threads, for example, necessitates machining the item after it has been removed from the mould. This lengthens the time and effort required to create a particular shape. Because of additive manufacturing, the part's intricacy does not result in higher expenses. Where previously numerous separate parts were required within a twisted or welded framework, only one element is now required. It can also be produced in a single piece.

METAL 3d Printing

INNOVATIVE TECHNOLOGIES

We Use the MetalX Markforged Printer

Our MetalX 3D Printer is highly customisable - allowing us to alter complex designs to solve specific problems. Test prints are standard procedure as part of our quality assurance.

For Bespoke Metal 3D Printing - A metal fused filament fabrication 3D printer can prototype and build low-volume products like bespoke impellers and nozzles. The tiny volume nature of these parts, as well as the intricate geometries required, fit under this application.

It can also be used to assist with casting - Die casting is a cost-effective method of producing complicated items in large quantities. However, prototyping these elements is too costly. Metal 3D Printing allows customers to print near nett form components to fine-tune cast part design before investing in expensive production tooling.

We are Engineers - We can help you make your 3D Design a reality talk to our team today. We will transform your rudimentary sketches into dynamic parts that are integral to making your ideas come to life.

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Stages of Metal 3D Printing Process

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Step 1 - Print Metal X

The material that is currently available with our Metal X printer is powdered metal, which is bounded together by a wax polymer that is then formed into a tube and wound around a spool. During the actual printing stage, we feed the material from the spool into an extruder nozzle that will print your part one layer at a time.

For certain geometry types we use physical supports as you cannot print in mid-air. To ensure they are not fused to the final part, a layer of powdered ceramic is printed in between the part and the support, creating a barrier for ease of separation.

Your part is what is referred to as a 'Green Part'. We print your part from 20 – 35% larger than their final dimension to accommodate both expansion and shrinkage. This scale up is determined by our software so there is no need to make another model for printing with different dimensions.

Step 2 - Chemical Wash

Once we have completed the 3D Printing process of your part, we need to remove as much of the wax polymer as possible.

Your part goes into a chemical bath with the length of time determined by our software and how much material is in the part. After the washing process, the part is then dried.

Weighing your part before and after the ‘Wash’ stage helps determine if enough wax has been removed before it goes into the third step.

Your part is now referred to as a ‘Brown Part’.

To determine if enough wax has been removed, we apply a simple formula to ensure your part falls within the fraction allowed in the sinter per part.

Metal 3D Printing - Chemical Wash - RetroCast 3D Printing Brisbane

Step 3 - Sinter Process

After your part has been printed and washed adequately, they can be placed in the sinter for their final step.

The Sintering is the process of fusing particles together into one solid mass by using a combination of pressure and heat, without melting the materials.

Only one material can be sintered at a time. This is to ensure parts aren't fused together.

Once the sintering process is complete, the part is removed from the furnace, supports are removed and any post processing is done (drilling, tapping, machining etc.).

Your product is now ready to be used.

Find Your Pathway to Innovation with RetroCast 3D Printing

Supporting businesses to Discover, Design and Develop, reliable and profitable additive manufacturing components sustaining their performance at their highest capacity.

3D Modelling

Conceptually having a tangible object can help you through the creative process. Retrocast 3D Printing will construct concept models that mimic the appearance of production-run parts.
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Test Your 3D Concept

Display your design and relay the marketability of your product. Create a market for your product before production. Send your 3D Concept to Retrocast 3D Printing to explore your options and get a quote.
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3D Performance Testing

We can test your new product is doable prior to full production. Rapid prototyping services allows us to test the form, fit, and function of your prototype.