3D Printing Aluminium.
3D Printing in Aluminium. Strong & Durable Service.
3D print your designs in Aluminium and choose from a range of alloys to suite your application.
Aluminium is 3D printed using the DMLS (Direct Metal Laser Sintering) or SLM process. A very fine metal powder is melted with a laser to produce your design layer by layer. Once your design is complete any support structures are removed and any finishing completed. Unused powder is recycled for use on the next model.
3D Printing in Aluminium can work out more cost effective than traditional 'subtractive' processes, especially where you have complex or intricate designs. Extra complexity does not add to the price of manufacture as it might with traditional manufacture.
AlSi10Mg is our default Aluminium material for 3d printing.
The alloy gives a homogeneous and almost pore free structure and is impermeable. AlSi10Mg offers high hardness values, and good dynamic strength. The nature of the DMLS or SLM process means that the mechanical properties of finished parts are better than traditional casting processes.
AlSi10Mg is ideal for design applications where you need good mechanical properties and low weight. Components 3d printed in the alloy can be subjected to a range of post build finishing processes, including heat-treatment, machining, welding, eroding, micro-blasting, polishing and coatings.
This alloy gives you a material with high thermal conductivity and low density. In addition it's composition gives it good strength and high chemical resistance.
The high copper content gives the alloy good high-temperature strength, which makes AlSi9Cu3 a good choice for engine and gear manufacturing. The reduced Si content in this alloyalso improves the machining properties while the combination of Si and Cu ensure the high mechanical strength. The low levels of Mg and Cu result in an increase in strength and enable the curing of this alloy.
This alloy is typically used to manufacture complex machine and engine parts, where it's properties make it ideal for transmission casings, cylinder heads and engine blocks.
Aluminium AlMgSc ( Scalmalloy®RP )
AlMgSc ( Scalmalloy®RP ) has been specifically designed for aerospace applications. The specific blend of elements gives AlMgSc improved strength over traditional casting alloys.
The strength of components can be considerably increased with a precipitation hardening process, to give a performance which is twice that of T6 heat treated AlSi10Mg.
Finally, parts produced from AlMgSc may be welded and exhibit excellent corrosion resistance.
With a strength to density ratio comparable to titanium the alloy is also very tough, making it ideal for safety critical designs.
Supporting information. 3D printing in Aluminium.
Our metal 3d printing service gives you an range of build envelopes of up to 400 x 400 x 360mm in AlSi10Mg. Other alloys have the following build envelopes:
- 400 x 400 x 360mm - Aluminium 'large format' (Alsi10Mg)
- 280 x 280 x 350mm - Aluminium 'standard' for faster turnaround. (Alsi10Mg)
- 250 x 250 x 300mm - Alsi9Cu3, AlMgSc ( Scalmalloy®RP )
Examples of our work.
Batch production in 3D printed Aluminium.
Batches of small, complex parts can work our cost effective using the 3d printing DMLS process.
A large format design for an automotive client.
Our 3DF printed aluminium service supports parts up to 400mm to enable large design to be printed in a single build.
3D Printing in Aluminium with post build machining.
A large format design showing post build machining where faces are machined off, holes drilled and threads added. This is a one off design, a component of a pure physics research project.
Solid Parts ? Yes as confirmed with a helium leak test.
We are often asked about the solidity of our 3d printed metal parts. A client decided to put it to the test and we produced a competent to undergo a helium leak test, which was passed with flying colours. Metal parts are typically better than 99.5% solid.
A 3D Printed 'impossible' onion style design with concentric inner walls.
3D Printing in metals is particularly effective with complex geometries designed for the process. The design pictured incorporates an especially complex internal design with wrapped concentric walls forming a cell structure. Powder removal was a challenge !
3D Printing in Aluminium for the re-manufacture of out of production components.
Scanning and 3d printing in metal give manufacturers an option to support legacy products 'on demand'. The part pictured is part of a trial to evaluate the possible savings in storage, cash flow and logistics. The 3D Printed version clearly shows the original weld line...
For important technical and ordering information on our 3d printing in metals, please see our general 'Metals' page.
3D Printed Materials
OUR CLIENTS SAY
Efficient and useful service allowed me to test prototypes in aluminium. Discussion allowed concentration on important features for testing. Speed of delivery good. Would recommend.
Great news! I won the Young Engineer for Britain: Engineering Excellence Award at the NEC Big Bang Fair yesterday. I'd just like to thank you again for your generosity and your excellent prints. I'll be sure to recommend your company in future and I wish you all the best.