Additive Manufacturing has evolved rapidly, allowing the creation of complex components using a variety of materials—including metals. Yet as with any engineering project, choosing metal 3D printing involves several decisions: the right printer, the right metal, and whether this process is truly the most suitable option. Understanding your design requirements and the metal 3D printing market is essential before committing to a path that may be costly if misjudged.
The First Step
After completing the first version of your 3D model in SolidFace, the next stage is prototyping for testing and analysis. With so many printers available, identifying where to begin becomes a challenge. As your research skills grow, you are better prepared to evaluate options objectively, starting with a fundamental question: which printer best fits your project?
Selecting the Right 3D Printer
Choosing a printer requires understanding your design’s limitations and requirements. Material selection is a major factor. If your prototype must be printed in metal, your list of compatible printers becomes narrower. Metal 3D printing is still more expensive than traditional manufacturing, with stainless-steel powder costing between $350 and $450 per kilogram. A comparative analysis of pricing, capabilities, and build volume is essential, especially since complex geometries may only be achievable through additive manufacturing.
Large-scale printers such as the X LINE 2000R from GE—one of the biggest in the industry—allow builds up to 800 × 400 × 500 mm. Knowing your maximum part size helps avoid choosing a machine that is either unnecessarily large or too small for your design. Making the wrong choice can be extremely costly.
Understanding Metal Properties in Additive Manufacturing
Mechanical properties of metal parts depend heavily on their manufacturing process. 3D printed metals often differ from their traditionally manufactured counterparts. Researchers continue to improve additive methods for applications such as fatigue resistance, but understanding these differences is essential when defining how a printed metal part will perform. Consulting material specialists familiar with metal 3D printing can help prevent design mistakes.
Buying a Metal 3D Printer or Using Professional Services?
Because of the high cost of metal printing, evaluating budget limits and project scope is crucial. While PLA filament costs around $20 per kilogram, metal powders can exceed $450 per kilogram. Errors become expensive quickly.
A practical approach is a two-stage prototyping strategy. First, create rapid prototypes in PLA to test ergonomics, functionality and design intent without focusing on material properties. Once validated, move to metal prototyping with specialized companies that already have the equipment and expertise. This minimizes risk and ensures metals are used only when your design is fully ready.
Final Thoughts
Choosing metal 3D printing requires careful research and thoughtful decision-making—just like any engineering task. With 3D modeling, you select the best tools; metal printing demands the same mindset. The technology is exciting, powerful, and increasingly accessible, making it a compelling option for complex designs. By staying informed and using strong digital tools like SolidFace to prepare and refine your models, you can fully embrace the advantages that metal 3D printing offers.
