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Aluminum 3D Printing

  • DMLS Parts In As Soon As 3 Days
  • Complex Metal Parts From A Variety of Alloys
  • Functional Metal Prototypes & End-Use Parts
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Aluminum 3D Printing

Fathom delivers high-quality aluminum parts to its valued customers using modern methods and the latest in Metal 3D Printing machinery. Fathom has the manufacturing solutions that will meet the needs of your time-sensitive, high-complexity, high-precision, or short production run related project.

Why Would You Choose Aluminum for 3D Printing? / /

Aluminum is a popular raw material that is lightweight and has good mechanical properties. Aluminum’s properties can be modified by applying different treatments, increasing ductility and conductivity. Treating aluminum can also improve its thermal and electrical conductivity. Aluminum is perfect for parts that must be gas tight. Known for having good casting properties, 3D printing aluminum can result in parts with thin walls and complex geometries. Additional aluminum features are its good strength, hardness, and dynamic properties, making it useful for parts subject to high loads.

Parts made from aluminum are appropriate for applications that call for good thermal properties and low weight. Aluminum parts can be machined, spark eroded, micro shot-peened, welded, polished, and coated. 

Aluminum parts often require heat treatment to improve their mechanical properties, including using the T6 cycle of solution annealing, quenching and age hardening. 

Laser sintering is known for extremely rapid melting and re-solidification, resulting in metallurgy and related mechanical properties in the as-built condition, like T6 heat-treated cast components. Heat treatment is unnecessary for laser-sintered parts; however, laser-sintered parts benefit from a stress-relieving cycle of 2 hours at 572 °F (300 °C). Parts have certain anisotropy due to the layerwise building method, which can be reduced or removed by heat treatment (see technical data).

Aluminum 3D Printing Services Offered By Fathom / /

Fathom offers additive layer technologies, including aluminum 3D printing. To produce a part using metal 3D printing, a laser beam melts 20 to 60 micron layers of powdered metal on top of each other. Metal 3D printing services offered by Fathom include selective laser melting (SLM), electron beam melting (EBM), laser deposition welding (LMD) and metal powder application (MPA). Fathom has 28 manufacturing technologies, including aluminum 3D printing.

Additive Manufacturing

  • FDM
  • SLS
  • SLA
  • Polyjet
  • MJF
  • DMLS
  • DLS
  • STEP (Evolve)

CNC Machining

  • CNC (3 & 5 Axis)
  • CNC Lathe
  • Precision Grinding
  • Wire & Sinker EDM

Injection Molding

  • Injection Molding
  • Tooling
  • Compression Molding

Metal Cutting and Forming

  • Thermoforming
  • Sheet Metal Punching
  • Sheet Metal Cutting
  • Metal Forming
  • Laser Cutting
  • Water Jet Cutting
  • Chemical Etching
  • Welding
  • Micro Cutting

Standalone

  • Die Casting
  • Urethane Casting
  • Composite Layups
  • Extrusion
  • Post Processing & Finishing
    • Pad Printing
    • Powder Coating
    • Bead Blasting
    • Surface Grinding
    • Polishing
    • Anodize
    • Powder Coat Passivate
    • Chemfilm
    • Vacuum Metallization
    • Silkscreen
    • Plating
    • Tumbled

Aluminum 3D Printing Quote Times / /

Use Fathom’s SmartQuote online platform for a quote within 1 to 24 hours. Do you want a quote for aluminum 3D printing, or do you want to learn about one of Fathom’s other manufacturing services? Fathom’s metal prototype lead times are as follows:

  • Parts as fast as 5 days

Aluminum 3D Printing Machines Used by Fathom / /

Over 530 machines power Fathom’s manufacturing facilities, including mills, lathes, presses, press brakes, turret punches, and additive systems. Fathom utilizes 12+ high-precision DMLS machines for metal 3D printing.

Fathom’s manufacturing technologies are not limited to aluminum 3D printing and include hybridized services leveraging 3D printing of all kinds. Ready for Metal 3D printing as part of a complex job? Fathom can do it.

A recent case study is listed below where Fathom delivered 20,000 parts in 27 days using 55+ tools, including multiple 3D printing services:

Case Study //

Real Customers. Real Results.

A customer came to Fathom with a complex project that spanned the technologies and processes of rapid production—and needed it done fast. Fathom delivered.

20,000 Parts // Within 27 Days
55+ Tools to Injection Mold 15,000 Parts First Article in 2 Weeks
15,000

55+ Tools to Injection
Mold 15,000 Parts

First Article in 2 Weeks

3,000+ 3D Printed Parts
3,000

3,000+ 3D
Printed Parts

2,000+ Metal Fabricated Parts
2,000

2,000+ Metal
Fabricated Parts

Hybridized Services Used //

3D Printing / Additive Manufacturing—PolyJet, SLS, MJF.

DFM Analysis + CAD Mods.

CNC Machining. Laser Cutting.

Stamping. Die Cutting. Post-Opp Drilling.

24-hour Turnaround Urethane Casting.

Injection + Compression Molding.

Model Finishing. Insert Assembly.

Advanced Project Management.

Fathom’s Locations for Aluminum 3D Printing / /

Two US-based Fathom locations offer aluminum 3D printing, offering nationwide coverage to the entire United States. Manufacturing and prototyping services include CNC machining, metal 3D printing, injection molding, CNC machining, etc. Fathom has provided over 200,000 quotes to the top US companies and is ready to quote you today.

Locations include:

HEADQUARTERS
1050 Walnut Ridge Drive
Hartland, WI 53029
ISO 9001:2015
AS9100:2016
ITAR

CALIFORNIA
620 3rd Street
Oakland, CA 94607
ISO 9001:2015 Design Certified
NIST 800-171 Compliant
ITAR

Aluminum AlSi10Mg Technical Data / /

EOS Aluminum AlSi10Mg is an aluminum alloy in fine powder form which has been specially optimized for processing on EOSINT M systems.

This document provides information and data for parts built using EOS Aluminum AlSi10Mg powder (EOS art.-no. 9011-0024) on the following system specifications:

  • EOSINT M 280 with PSW 3.6 and Original EOS Parameterset AlSi10Mg_Speed 1.0
  • EOS M 290 400Watt with EOSPRINT 1.0 and Original EOS Parameterset AlSi10Mg_Speed 1.0

Description / /

AlSi10Mg is a typical casting alloy with good casting properties and is typically used for cast parts with thin walls and complex geometry. It offers good strength, hardness and dynamic properties and is therefore also used for parts subject to high loads. Parts in EOS Aluminum AlSi10Mg are ideal for applications which require a combination of good thermal properties and low weight. They can be machined, spark-eroded, welded, micro shot-peened, polished, and coated.

Conventionally cast components in this type of aluminum alloy are often heat treated to im- prove the mechanical properties, for example using the T6 cycle of solution annealing, quenching and age hardening. The laser-sintering process is characterized by extremely rapid melting and re-solidification. This produces a metallurgy and corresponding mechanical proper- ties in the as-built condition which is similar to T6 heat-treated cast parts. Therefore, such hardening heat treatments are not recommended for laser-sintered parts, but rather a stress re- lieving cycle of 2 hours at 300 °C (572 °F). Due to the layerwise building method, the parts have a certain anisotropy, which can be reduced or removed by appropriate heat treatment – see Technical Data for examples.

Technical Data / /

General process and geometrical data

Typical achievable part accuracy [1] [2] ± 100 µm
Smallest wall thickness [1] [3] approx. 0.3 – 0.4 mm
approx. 0.012 – 0.016 inch
Surface roughness, as built, cleaned [1] [4] Ra 6 – 10 µm, Rz 30 – 40 µm
Ra 0.24 – 0.39 x 10-³ inch
Rz 1.18 – 1.57 x 10-³ inc
– after micro shot-peening Ra 7 – 10 µm, Rz 50 – 60 µm
Ra 0.28 – 0.39 x 10-³ inch
Rz 1.97 – 2.36 x 10-³ inch
Volume rate [5] 7.4 mm³/s (26.6 cm³/h)
1.6 in³/h

[1] These properties were determined on an EOSINT M 270.
[2] Based on users’ experience of dimensional accuracy for typical geometries. Part accuracy is subject to appropriate data preparation and post-processing, in accordance with EOS training.
[3] Mechanical stability dependent on the geometry (wall height etc.) and application
[4] Due to the layerwise building, the surface structure depends strongly on the orientation of the surface, for example sloping and curved surfaces exhibit a stair-step effect. The values also depend on the measurement method used. The values quoted here given an indication of what can be expected for horizontal (up-facing) or vertical surfaces.
[5] The volume rate is a measure of the building speed during laser exposure. The overall building speed is dependent on the average volume rate, the time required for coating (depends on the number of layers) and other factors, e.g. DMLS settings

Physical and chemical properties of the parts / /

Material composition Al (balance)
Si (9.0 – 11.0 wt-%)
Fe (≤ 0.55 wt-%)
Cu (≤ 0.05 wt-%)
Mn (≤ 0.45 wt-%)
Mg (0.2 – 0.45 wt-%)
Ni (≤ 0.05 wt-%)
Zn (≤ 0.10 wt-%)
Pb (≤ 0.05 wt-%)
Sn (≤ 0.05 wt-%)
Ti (≤ 0.15 wt-%)
Relative density approx. 99.85%
Density 2.67 g/cm³
0.096 lb/in³

Mechanical properties of the parts / /

As built Heat treated [9]
Tensile strength [6]
– in horizontal direction (XY) 460 ± 20 MPa
66.7 ± 2.9 ksi
345 ± 10 MPA
50.0 ± 1.5 ksi
– in vertical direction (Z) 460 ± 20 MPa
66.7 ± 2.9 ksi
350 ± 10 MPa
50.8 ± 1.5 ksi
Yield strength (Rp 0.2 %) [6]
– in horizontal direction (XY) 270 ± 10 MPa
39.2 ± 1.5 ksi
230 ± 15 MPa
33.4 ± 2.2 ksi
– in vertical direction (Z) 240 ± 10 MPa
34.8 ± 1.5 ksi
230 ± 15 MPa
33.4 ± 2.2 ksi
Modulus of elasticity
– in horizontal direction (XY) 75 ± 10 GPa
10.9 ± 0.7 Msi
70 ± 10 GPa
10.2 ± 0.7 Msi
– in vertical direction (Z) 70 ± 10 GPa
10.2 ± 0.7 Msi
60 ± 10 GPa
8.7 ± 0.7 Msi
Elongation at break [6]
– in horizontal direction (XY) (9 ± 2) % 12 ± 2%
– in vertical direction (Z) (6 ± 2) % 11 ± 2%
Hardness [7] approx.119 ± 5 HBW
Fatigue strength [1] [8]
– in vertical direction (Z) approx. 97 ± 7 MPa
approx. 14.1 ± 1.0 ksi

[6] Mechanical strength tested as per ISO 6892-1:2009 (B) annex D, proportional specimens, specimen diameter 5 mm, original gauge length 25 mm (1 inch).
[7] Hardness test in accordance with Brinell (HBW 2.5/62.5) as per DIN EN ISO 6506-1. Note that measured hardness can vary significantly depending on how the specimen has been prepared.
[8] Fatigue test with test frequency of 50 Hz, R = -1, measurement stopped on reaching 5 million cycles without fracture.
[9] Stress relieve: anneal for 2 h at 300 °C (572 °F).
[10] These properties were determined on an EOSINT M 280-400W. Test parts from following machine type EOS M 290-400W correspond with these data.

Thermal properties of parts / /

As built [1] Heat treated [1] [9]
Thermal conductivity (at 20 °C)
– in horizontal direction (XY) approx. 103 ± 5 W/m°C approx. 173 ± 10 W/m°C
– in vertical direction (Z) approx. 119 ± 5 W/m°C approx. 173 ± 10 W/m°C
Specific heat capacity
– in horizontal direction (XY) approx. 920 ± 50 J/kg°C approx. 890 ± 50 J/kg°C
– in vertical direction (Z) approx. 910 ± 50 J/kg°C approx. 890 ± 50 J/kg°C

Alsi10mg FAQ / /

Q: Does Fathom work with Alsi10mg?

A: Yes, Fathom works with Aluminum.

Q: What is Alsi10mg?

A: Alsi10mg is a common type of casting alloy that has good casting properties. Aluminum is a good match for parts that have thin walls and complex geometries. 

Q: Is Fathom ISO certified?

A: Fathom’s certifications include ISO 9001:2015, ISO 9001:2015 Design, and ISO 13485:2016. 

Q: Is Fathom ITAR certified?

A: Fathom is ITAR certified.

Q: Is Fathom AS9100:2016 certified?

A: Yes, Fathom is AS9100:2016 certified.

Q: Is Fathom NIST 800-171 certified?

A: Fathom’s certifications include NIST 800-171.

Q: What is AlSi10Mg used for?

A: AlSi10Mg is used to make ductwork, tools, engine parts, housings, etc.

Q: Can you weld AlSi10Mg?

A: Yes, AlSi10Mg can be welded without adding filler material. The resulting weld has added strength.

Q: Can aluminum be 3D printed?

A: Yes, aluminum can be 3D printed.

Q: How much does 3D printing aluminum cost?

A: The cost of 3D printing aluminum varies by the quantity ordered, amount of material needed, the complexity of design, labor and more.

Q: Why is aluminum hard to 3D print?

A: Aluminum is suitable for 3D printing, but some post-processing and surface finishing is needed. 

Q: How strong is 3D printed aluminum?

A: 3D printed parts can be stronger than components made using traditional manufacturing technologies.

Aluminum 3D Printing Quotes / /

Are you ready to receive a quote on your aluminum 3D printing project? Do you need an estimate? Get started today by submitting your file to Fathom’s SmartQuote online platform. Our team will send you a quote within 24 hours.

Manufacturing Locations Across National Time Zones
Manufacturing Locations Across National Time Zones
The Fathom Advanced Manufacturing Platform
new map update 3
HEADQUARTERS

1050 Walnut Ridge Drive
Hartland, WI 53029
ISO 9001:2015
AS9100:2016
ITAR

ARIZONA

444 W. 21st St. Ste. 101
Tempe, AZ 85282
ISO 9001:2015
NIST800-171 Compliant
ITAR

COLORADO

7770 Washington St.
Denver, CO 80229
ISO 9001:2015
ITAR

MINNESOTA

13758 Johnson Street NE
Ham Lake, MN 55304

TEXAS

1801 Rowe Lane
Pflugerville, TX 78660
ISO 9001:2015
AS9100:2016

1513 Sam Bass Rd
Round Rock, TX 78681
ISO 9001:2015
ISO 13485:2016

CALIFORNIA

620 3rd Street
Oakland, CA 94607
ISO 9001:2015 Design Certified
NIST 800-171 Compliant
ITAR

FLORIDA

14000 N.W. 58th Court
Miami Lakes, FL 33014

NEW YORK

1920 Slaterville Rd
Ithaca, NY 14850
ITAR

401 W. Shore Blvd.
Newark, NY 14513
AS9100:2016
ISO 9001:2015
ITAR

ILLINOIS

1207 Adams Drive
McHenry, IL 60051
ISO 9001:2015

1401 Brummel Ave
Elk Grove, IL 60007
ISO 9001:2015 Design Certified