Fathom uses the latest in metal 3D Printing technologies to deliver high-quality parts to its customers. Whether time-sensitive, highly complex, high-precision, or short production run related, Fathom will meet the requirements of your project.
Several important factors determine the cost of metal 3D printing, including the design, material, quantity ordered, and turnaround time.
Printing a part with complex geometries can be cost-effective when using metal 3D printing. When designing for 3D printing, it is important to include self-supporting angles to eliminate the need for supports and cut down on material. The design should also focus on the performance of the part and reducing the number of parts needed to complete a larger piece to reduce assembly time.
A wide range of metals can be used for metal 3D printing, from aluminum to titanium. Metals with better performance properties, such as chemical resistance, are more expensive. To save on cost, select a material based on how the part is expected to perform and the environment in which it will operate.
Metal 3D printing is perfect for projects that require a lower volume of parts or a variety of customizations. Metal 3D printing does not require tools to be developed for every part, allowing for more design flexibility. For example, a project that asks for ten versions of a single part can be made cost-effectively using metal 3D printing.
Turnaround times for metal 3D printing are reduced as secondary processes such as finishing or assembly are often unnecessary. For projects that do require a higher quality finish, post-processing is available, including abrasive blasting, shot peening, electroplating and more. If a secondary finish is needed using an all-in-one manufacturer who offers both metal 3d printing and secondary finishing services will help to reduce lead time.
Fathom offers Direct Metal Laser Sintering (DMLS), otherwise known as metal 3D printing or Direct Metal Laser Melting (DMLM), an additive layer technology. During metal 3D printing, a laser beam melts 20-60 micron layers of powdered metal on top of each other, creating a part out of a bed of powdered metal. Fathom’s metal 3D printing services include selective laser melting (SLM), electron beam melting (EBM), laser deposition welding (LMD) and metal powder application (MPA). Metal 3D printing is one of 28 manufacturing processes offered by Fathom.
Take advantage of Fathom’s SmartQuote online platform and receive a quote in as little as 1 hour, usually within 24 hours. Do you need a metal 3D printing quote, or would you like to learn about another manufacturing service? Fathom’s metal prototype lead times are as follows:
Fathom’s manufacturing facilities are powered by over 530 machines, including mills, lathes, presses, press brakes, turret punches and additive systems. Fathom runs 12+ high-precision DMLS machines specific to metal 3D printing.
Fathom provides not just Metal 3D printing services but also hybridized services leveraging 3D printing of all kinds. Need Metal 3D printing as part of a more complex project? Fathom can handle 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.
Fathom offers Metal 3D printing with nationwide coverage to the entire United States. Fathom’s advanced prototyping and manufacturing services include injection molding, CNC machining, chemical etching, metal 3D printing, and more. We have provided over 200,000 quotes to leading US companies and are ready to provide you with a quote today.
Locations include:
HEADQUARTERS
1050 Walnut Ridge Drive
Hartland, WI 53029
ISO 9001:2015
AS9100:2016
ITAR
Metal 3D printing produces durable, complex, intricate, and elaborate parts from metal powders. Designing the part to use minimal support structures or with a self-supporting design will greatly reduce cost. When printing, the orientation of the part can affect the surface finish as upward-facing surfaces have sharper edges and a better finish. Wall thickness, pin diameter, hole size, escape holes, over hangs, unsupported edges, aspect ratio, and tolerances all vary based on the method of 3D printing used.
| Material | Alloy Designation | Layers | Hardness | Advantages | Applications |
|---|---|---|---|---|---|
| Stainless Steel (PH1) | 15-5 PH, DIN 1.4540 & UNS S15500 | 20 or 40 Micron Layers | 30-35 HRC Built, Post Hardened to 40 HRC | High Hardness & Strength | Prototype / Production Parts |
| Stainless Steel (GP1) | 17-4, European 1.4542, German X5CrNiCuNb16-4 | 20 or 40 Micron Layers | 230 ± 20 HV1 Built, Ground & Polished to 250-400 HV1 | High Toughness & Ductility | Engineering Applications |
| Cobalt Chrome (MP1) | ISO 5832-4 & ASTM F75 | 20, 40 or 50 Micron Layers | 35-45 HRC Built | High Temperature Resistance | Turbines & Engine Parts |
| Maraging Steel (MS1) | 18% Ni Maraging 300, European 1.2709, German X3NiCoMoTi 18-9-5 | 20 or 40 Micron Layers | 33-37 HRC Built, Post Hardened to 50-56 HRC | Easily Machinable & Excellent Polishability | Injection Molding Tooling, Conformal Cooling |
| Aluminum AlSi10Mg | Typical Casting Alloy | 30 Micron Layers | Approx. 119 ± 5 HBW | Low Weight, Good Thermal Properties | Automotive, Racing |
| Nickel Alloy IN718 | UNS N07718, AMS 5662, AMS 5664, W.Nr 2.4668, DIN NiCr19Fe19NbMo3 | 40 Micron Layers | 30 HRC Built, Post Hardened 47 HRC | Heat & Corrosion Resistant | Turbines, Rockets, Aerospace |
| Stainless Steel (316L) | ASTM F138 | 20 Micron Layers | 85 HRB | Corrosion & Pitting Resistant | Surgical Tools, Food & Chemical Plants |
| Titanium Ti-64* | ASTM F2924 | 30 or 60 Micron Layers | 320 ± 15 HV5 | Light Weight, High Strength & Corrosion Resistant | Aerospace, Motorsport Racing |
| Titanium Ti-64 ELI* | ASTM F136 Properties | 30 or 60 Micron Layers | 320 ± 15 HV5 | Corrosion Resistance, Biocompatibility | Medical, Biomedical, Implants |
Fathom offers high-quality metal 3D printing. Materials available include:
Metal parts made using 3D printing have multiple benefits. Metal 3D printed parts weigh less and require less assembly. Using 3D printing, companies can make parts with complex geometries that may not have been possible using other manufacturing methods. A wide variety of metal materials may be used in the 3D printing process, including superalloys. Metal 3D printing works for a wide number of industries, facilitating advancement and innovation.
Several finishing methods can help a part achieve a professional surface finish. The finishing process can add strength, rust resistance, and metal conductivity to a part while improving its appearance. Some of the finishing processes offered by Fathom include shot peening, electrochemical polishing, CNC finishing and more.
Abrasive blasting removes imperfections, rust, or other contaminants from the surface of a part. It is often used in preparation for a coating application. Abrasive blasting methods include micro-abrasive blasting, bristle blasting, bead blasting, and more. Steel grit, silicon carbide, pumice, and other abrasive materials may be used during the abrasive blasting.
Shot peening is used to add strength and reduce the stress profile of a part. During the shot peening process, the surface of the part is hit with multiple shots which cause deformation on the part’s surface. After shot peening, the part has a compressive stressed layer.
Optical polishing is used to create a microfinish or superfinish on a surface for further processing. It is best used on projects with geometries in low quantities that are not tolerance dependent. Optical polishing is a cost-effective finishing method that provides a brilliant finish.
Electrochemical polishing produces a mirror-like finish on metal surfaces and is sometimes used to prepare a metal part for additional finishing. During electrochemical polishing, the part is placed into an electrolytic solution alongside a cathode of copper or lead. An electric current moves through the solution, smoothing the part’s surface.
Abrasive flow machining is used for deburring and to polish parts. Abrasive flow machining uses chemically inactive media. The abrasive works to polish the part and remove any unwanted material.
Electroplating adds a metal layer to the outside of a part, increasing its strength and durability. Electroplating dissolves metal in an electrolytic solution and transfers it onto the surface of the part. Some of the most common metals used during electroplating are copper and zinc.
The micro machining process is used to produce a mirror-like finish with great technical precision while preserving the geometries of the part. During MMP, the part is first mapped using a profilometer to create a roughness profile. The part is then moved to an MMP envelope where micro-milling cutters begin to polish the part.
CNC finishing methods can improve a part’s wear resistance, metal conductivity, strength, rust resistance and more. CNC machining can also improve the look of a part and make it easier to apply a final coating. Depending on the type of surface finish needed, finishing may involve several different methods, including powder coating, bead blasting, passivation or anodizing.
Parts made using metal 3D printing are lightweight, strong, and durable. Aerospace, healthcare, research and development, and automotive are just a few industries that use metal 3D printing to make goods. Examples of metal 3D printed parts include:
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: Yes, 3D printers can print metal.
A: Metal parts made using 3D printing may be up to 3x stronger than those made using conventional methods.
A: Stainless steel, nickel, and titanium are just a few of the different kinds of metal used in 3D printing.
A: The cost of 3D printing varies by project depending on the design, quantity, raw material, and time needed to complete a job.
Are you looking to get Metal 3D printing quotes or calculate costs for an upcoming project? Fathom’s SmartQuote application provides fast quotes for any file.
