Real Metal. Not Metal-Filled Plastic.

Metal 3D printing — also called Direct Metal Laser Sintering (DMLS) or Selective Laser Melting (SLM) — produces fully dense metal parts by fusing metal powder with a high-powered laser, layer by layer. The resulting parts have mechanical properties comparable to wrought or cast metal.

This isn’t metal-infused plastic. It’s not a metal-coated prototype. It’s actual metal — titanium, stainless steel, aluminum, Inconel, cobalt chrome — built to near-net shape and ready for machining, heat treatment, and end-use deployment.

How Metal 3D Printing Works

  • A thin layer of metal powder (20–60 microns) is spread across the build platform
  • A high-powered fiber laser (200–400W+) selectively melts the powder according to the part geometry
  • The platform drops by one layer (typically 20–50 microns), and fresh powder is spread
  • The process repeats — hundreds or thousands of layers build the final part
  • Post-processing: stress relief, support removal, heat treatment, CNC finish machining as required

Build times are measured in hours to days. A small bracket might take 4–8 hours. A complex aerospace component might take 40+ hours. This is not a rapid prototyping process in the traditional sense — it’s a manufacturing process for parts that can’t be made any other way.

When Metal 3D Printing Makes Sense

Choose metal AM when:

  • Geometry can’t be machined — internal cooling channels, organic/topology-optimized shapes, lattice structures. If a 5-axis CNC can’t reach it, metal AM can build it.
  • Material is exotic or expensive — titanium, Inconel, cobalt chrome. Metal AM wastes very little material (buy-to-fly ratio) compared to machining a billet.
  • Weight reduction is critical — topology optimization + metal AM can reduce part weight by 40–60% while maintaining strength. Aerospace and motorsport live here.
  • Quantity is low — tooling-free process. One part or fifty parts, the unit economics scale differently than casting or forging.
  • Lead time beats traditional methods — no tooling procurement. Design to part in 1–3 weeks vs. 8–16 weeks for investment casting.

Common applications:

  • Aerospace brackets, ducting, and structural components (Ti-6Al-4V)
  • Conformal cooling channels in injection mold tooling (maraging steel)
  • Medical implants — hip cups, spinal cages, cranial plates (Ti-6Al-4V ELI, CoCr)
  • Turbine components and heat exchangers (Inconel 625/718)
  • Motorsport and performance automotive components
  • Tooling inserts with internal cooling that cut cycle times by 30–50%

Available Metals

Material Key Properties Typical Applications
Ti-6Al-4V (Titanium) Highest strength-to-weight ratio, biocompatible, corrosion resistant Aerospace structural, medical implants, motorsport
316L Stainless Steel Corrosion resistant, good ductility, cost-effective Marine, food processing, general engineering
17-4 PH Stainless High strength, hardenable, good corrosion resistance Aerospace, defense, industrial machinery
Inconel 625 Extreme temperature resistance (up to 980°C), corrosion resistant Turbine components, exhaust systems, chemical processing
Inconel 718 High strength at elevated temperatures, weldable Jet engine components, nuclear, oil & gas
AlSi10Mg (Aluminum) Lightweight, good thermal conductivity Heat sinks, automotive, drone structures
Maraging Steel (MS1) Very high hardness after aging, excellent machinability Injection mold tooling with conformal cooling
CoCr (Cobalt Chrome) Biocompatible, high hardness, wear resistant Dental, medical implants, turbine blades

What Metal AM Is NOT Good For

Honest assessment:

  • Large, simple parts — if it’s a rectangular bracket that can be waterjet-cut from plate, don’t 3D print it. CNC is faster and cheaper.
  • High volumes — above a few hundred parts, casting or forging will beat metal AM on unit cost every time.
  • Tight tolerances without post-machining — as-printed tolerance is typically ±0.1–0.2mm. Critical surfaces need CNC finishing.
  • Smooth surface finish — as-printed surfaces are rough (Ra 6–15μm). Functional or cosmetic surfaces require machining, polishing, or bead blasting.
  • Cost-sensitive applications — metal AM is expensive. A small part might run $200–500. A large complex component can be $2,000–10,000+. If the geometry doesn’t demand it, traditional manufacturing is almost always cheaper.

How PartSnap Delivers Metal AM

Metal 3D printing requires significant expertise in design, orientation, support strategy, and post-processing. We provide:

  • Design for Additive Manufacturing (DfAM) — optimizing your part for the metal AM process. This isn’t optional — a part designed for CNC machining will fail or cost 3x more if printed without modification.
  • Process selection — is metal AM actually the right choice? We’ll tell you honestly if CNC, casting, or sheet metal makes more sense for your application.
  • Production management — we work with qualified metal AM facilities and manage the full process: build, stress relief, heat treatment, finish machining, inspection, and delivery.
  • Material certification — mill certs, material test reports, and dimensional inspection as required for your industry.

Get a Metal 3D Printing Quote

Upload your STEP or STL file and tell us about the application — material, quantity, critical dimensions, and any certifications required. We’ll provide a quote and an honest recommendation on whether metal AM is the right path.

Request a Quote →

info@partsnap.com · 214.449.1455