Using standard fused filament fabrication (FFF) for metal 3D printing offers new possibilities and a galaxy of benefits.
First of all, metal filaments can be printed on all common FFF printers – it is one of the easiest and relatively inexpensive technologies in additive manufacturing. Additionally, FFF is uniquely positioned to enable hollow structures and lightweight designs. Metal FFF transitions these benefits into the metal world. On top of this, users benefit from the traditional advantages a metal material brings along, such as corrosion resistance and outstanding strength.
Metal FFF Has Come a Long Way
So, it’s true to say that metal 3D printing has made quantum leaps in recent years and is now more accessible and scalable than ever before. The rapid analysis capabilities of virtual simulation tools and the latest generation of filaments are now unlocking the full potential of metal FFF 3D printing.
Together with the experts from Forward AM by BASF, let’s take a closer look at this exciting technology and what it takes to make it work!
In the video tutorial series, the experts of Forward AM by BASF share their tips and tricks to make your 3D metal printing project work.
What is Metal Filament?
For starters, it is essential to know that metal filament material combines metal powders and binders to print the desired geometry. Once printed, catalytic debinding and sintering processes are applied to remove the binder and to produce the final, full metal part. The catalytic debinding technology was developed and introduced by BASF and has emerged as the industry standard. To see whether your parts are ready for this industrially proven process, various simulations can be applied at each process stage:
As explained in the video tutorial, during catalytic debinding the binding agents are removed in preparation for final sintering. This can cause a loss of stability and structural integrity in the printed component. The result of the debinding process, the ‘brown part,’ can be quite fragile depending on its individual geometry and features. Lacking stability, parts not suited to this process can suffer from distortion or even collapse under their own weight.
What Can Be Done to Avoid Instability?
3D printed component design and printing orientation play crucial roles in successful debinding and sintering. If gravitational forces cause tensile and compressive stresses above a certain limit, a component can no longer maintain its shape.
To reduce the risk of collapse, the Virtual Engineering Team of Forward AM recommends performing a debinding stability simulation before printing. This provides an estimation of internal stresses to evaluate the part’s structural integrity during debinding – and also gives a visual indication of which structural features are at risk. With the Debinding Stability Simulation Guideline from Forward AM, you can quickly and easily determine which features may not yet be optimal for metal filament printing.
Analyzing for Internal Stress During Debinding
Besides checking a component’s features for potential critical stresses, it is important to select the most stable orientation for it during debinding. The right reorientation of a component can significantly reduce internal stresses, increase its survivability, and remove the need for redesign. Especially for components that take advantage of the increased structural complexity provided by today’s metal filament printing, it may not be obvious to new users which features might be critical. A Virtual Orientation Simulation can determine the optimal debinding orientation, giving your component the best possible outcome.
Once debinding is complete, sintering is carried out to produce the full metal component. During sintering, the printed parts undergo anisotropic shrinkage. Additionally, specific geometric characteristics can lead to warpage in the final printed part. With the Virtual Sintering Simulation, shrinkage and warpage effects can be accurately predicted to help minimize the time-consuming and costly need for trial-and-error-loops. The optimization program determines the correct pre-warped and pre-scaled “green part” geometry to produce the pre-finishing final part.
Supported by the corresponding simulations, metal FFF enables an easy, affordable and successful production of metal parts! To learn more, watch the complete tutorial series here.
Do you prefer to order full metal parts printed with Ultrafuse® 316L, the metal filament of Forward AM, already debound and sintered? Head over to the Sculpteo printing platform and upload your file quickly and easily. If you prefer printing the parts by yourself, find your local distributor for the metal filament UItrafuse® 316L here.
To discover more about Forward AM, the brand of BASF 3D Printing Solutions, check out “Forward AM: Portrait of an Innovative AM Company“.
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