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.
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).
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.
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:
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:
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.
55+ Tools to Injection
Mold 15,000 Parts
First Article in 2 Weeks
3,000+ 3D
Printed Parts
2,000+ Metal
Fabricated Parts
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.
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
46758 Lakeview Blvd
Fremont, CA 94538
ISO 9001:2015 Design Certified
NIST 800-171 Compliant
ITAR
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:
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.
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
| 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 |
| 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.
| 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 |
A: Yes, Fathom works with Aluminum.
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.
A: Fathom’s certifications include ISO 9001:2015, ISO 9001:2015 Design, and ISO 13485:2016. For site-specific certifications, please visit https://fathommfg.com/fathom-manufacturing-certifications.
A: Yes, Fathom is ITAR certified. For site-specific certifications, please visit https://fathommfg.com/fathom-manufacturing-certifications.
A: Yes, Fathom is AS9100:2016. For site-specific certifications, please visit https://fathommfg.com/fathom-manufacturing-certifications.
A: Yes, Fathom’s certifications include NIST 800-171. For site-specific certifications, please visit https://fathommfg.com/fathom-manufacturing-certifications.
A: AlSi10Mg is used to make ductwork, tools, engine parts, housings, etc.
A: Yes, AlSi10Mg can be welded without adding filler material. The resulting weld has added strength.
A: Yes, aluminum can be 3D printed.
A: The cost of 3D printing aluminum varies by the quantity ordered, amount of material needed, the complexity of design, labor and more.
A: Aluminum is suitable for 3D printing, but some post-processing and surface finishing is needed.
A: 3D printed parts can be stronger than components made using traditional manufacturing technologies.
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. Our team will send you a quote within 24 hours.
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877-328-4668
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