The latest advances in 3D printing technology for the metalworking industry

In the era of industry 4.0, metal 3D printing is becoming one of the commonly used technologies in the mechanical manufacturing industry. With the ability to create accurate products, low error rates and high flexibility, metal 3D printing technology is gradually replacing traditional processing methods. In this article, we will learn about metal 3D printing, how it works, common technologies, compare with CNC machining and contact METALEX Vietnam 2024.

1. What is metal 3D printing?

1.1. Concept

Metal 3D printing is an advanced method of metalworking, allowing for more complex and precise parts to be created by fabricating them with metal 3D printers. Common technologies include: 3D spray metal adhesives, powder layer fusion, and directional energy deposition. However, there are also some disadvantages such as high cost and slower production time compared to traditional metalworking methods such as CNC machining.

1.2. Pros & Cons

Some of the advantages of metal 3D printing include:

• High flexibility and customization: allow the production of highly complex models and products that can be easily customized according to customer needs.
• Production cost savings: Manufacturing a product using metal is often cost-effective compared to traditional methods such as mechanical processing or casting.
• Increase production speed: can produce faster and more efficiently than traditional methods.
• High precision: With the support of computers and 3D design software, metal 3D printing enables the high-precision production of products.
• No need for expensive tools: During the printing process, there is no need to use expensive tools to produce a part as in traditional mechanical machining.

Some of the disadvantages include:

• High initial investment costs: The printers are very expensive and the operating and maintenance costs are also relatively high.
• Slow production time: Compared to traditional manufacturing methods, this type of printing may take longer to produce the same product.
• Size and accuracy limits: there are still limits to size and accuracy compared to traditional metalworking methods.
• Limited materials: Currently, 3D printers can only print certain types of metals and there are still restrictions on other materials such as ceramic, plastic, etc.
• Using metal 3D printers requires highly specialized skills, especially in 3D model design and production process management.

1.3. Some applications: ring molds, braces, …

Metal 3D printinghas a wide range of applications in metalworking, from mold manufacturing, to machine parts, jewelry, braces, and more. Metal 3D models created with metal 3D printers can be used to produce precise mechanical parts, reducing production time, saving costs and minimizing scrap.  Metal 3D printing technology is increasingly being applied in industries such as aerospace, healthcare, automotive, and many others.

1.4. How are 3D printing and CNC machining different?

Metal 3D printing and CNC metalworking are two production technologies that have many differences. In particular, metal 3D printing is the process of building 3D metal models by adding continuous layers of metal on top of each other through a printer, while CNC metalworking is the process of removing material to create the final product by cutting, milling or turning metal according to a pre-programmed design.

Another difference is the time and cost of production. While metal 3D printing can produce complex products quickly and can save production costs with a small number of products, CNC machining is more suitable for large quantities of products and longer production times. In addition, CNC machining can also produce metal parts with greater precision than metal 3D printing models.

2. How does Metal 3D Printing work?

The metal 3D printing process begins with creating a 3D model using design software or 3D scanning of an already existing product. The model is then transferred to a metal 3D printer to start the printing process.

The most common metal 3D printing technology today is DMLS (Direct Metal Laser Sintering), in which metal powders are used as input materials. The metal powder is fed into the sprayer tank, after which a small amount of powder is sprayed out in each surface layer of the product.

A laser used to run through the powder layer and heat the powder up to sintering temperature, sintering is the process of binding metal powders together to form the final product. This process is repeated until the finished product and has high accuracy and detail.

After the printing process is complete, the product is removed from the spray pool and goes through several final finishing stages such as peeling off the mixture of metal powders and other materials. Finally, metal 3D printing products will be additionally machined to finish the surface and achieve the best quality.

3. Common metal 3d printing technologies

3.1. 3D Spray Metal Adhesive

This technology uses a laser to melt and spray powdered metal particles into the surface of the product. An adhesive is sprayed up to form an adhesive layer between the powder metal particles. After that, the powder spraying process is continued to form layers, until the product is complete.

3.2. Powder layer fusion

This technology uses a laser to melt a layer of metal powder on the surface of a product. After the first layer is formed, the product is introduced into another chemical metal material, creating a chemical reaction and precipitating, forming the next layer. This process is repeated until the product is complete

3.3. Directional energy deposition

This technology uses a laser to melt a layer of metal powder on the surface of a product. The laser is then shifted upwards to create the next layer and continues this process until the finished product. This technology allows for the creation of very thin and delicate details.

4. METALEX Vietnam 2024

METALEX Vietnam 2024 organized by RX Tradex is the largest specialized exhibition of metalworking machinery, technology and services in Vietnam. This event is held annually in Ho Chi Minh City and attracts a large number of experts in the mechanical industry, especially in the field of metalworking.

At the exhibition, companies will showcase the latest products, services and technologies in the industry, as well as a place for experts and businesses in the field of mechanics and metals to exchange, learn and establish cooperative relationships. METALEX Vietnam 20234 is expected to bring visitors a lot of useful information about the latest trends in the mechanical engineering and metalworking industry, in which metal 3D is one of the advanced technologies attracting a lot of attention from many companies, businesses will want to learn and experience this technology.  At METALEX Vietnam 2024, there will be many booths of suppliers of metal 3D printers and advanced metal production technologies, giving customers the choice and experience of the latest technology.