Metal 3D Printing

How does the process work?

The process is divided into 3 steps: printing a part with the BCN3D Epsilon 3D printers and the subsequent industry standardized debinding and sintering, done externally through Forward AM’s current authorized network of suppliers. The result is a final part which is nearly 100% solid stainless steel.

For the printing process, filaments Ultrafuse® 316L and 17-4 PH contain high levels of stainless steel in combination with polymer binders which allow easy printing. The binder content from the printed part is removed through a catalytic debinding process. For the next step, the part undergoes a subsequent sintering process at temperatures right below the melting temperature of the metal, which causes the metal particles to coalesce. The material then reaches its final state through post-sintering, where it achieves required performances in aspects such as hardness and strength.

The user workflow is reflected in the following picture.

The recommended BCN3D & BASF D&S provider that offer sintering and debinding services is:

CMG (UK & Europe) :

• CMG runs D&S cycles almost every week. They have one of the quickest delivery times in the market.
• CMG charges according to the occupied space in the oven, meaning that the cost will depend on how much space your parts will take up.
• They allow to debind and sinter parts up to 200mm x 300mm x 100mm, and are open to discussing even larger parts.
• They provide a wide range of post-processing services, including machining and polishing.

Find out more about the debinding and sintering process here

The process explained

How to install the Metal Pack

The installation of the Metal Pack on your Epsilon printer is extremely easy and quick. Follow the instructions in the following video to ensure a seamless installation: https://support.bcn3d.com/knowledge/metal-pack-install

Design requirements and guidelines

Our customer support team has prepared some documentation in our knowledge base to make sure you maximize the use of the metal pack:

• How to print 316L: https://support.bcn3d.com/knowledge/316l-filament
• 316L, tips and tricks: https://support.bcn3d.com/knowledge/316l-bcn3d-tips
• How to print 17-4 PH: https://support.bcn3d.com/knowledge/17-4ph-filament
• 17-4 PH, tips and tricks: https://support.bcn3d.com/knowledge/17-4-ph-bcn3d-tips

In the following guidelines from manufacturer BASF, you will learn about:

• Process Workflow
• Debinding Simulation
• Part Orientation
• Shrinkage & Sintering Distortion
• Supports “Not Just for Printing”
• Debinding & Sintering
• Post-Processing

Video training from basf

Module 1: Introducing Metal 3D Printing

Module 2: Process

Module 3: Design Guidelines

Module 4: Simulation Services

Properties

We carried out several tests at BCN3D to properly understand the final results that can be obtained with our printers. The following are the best results we’ve achieved with metal. We strongly recommend that you create your own iterations to get the right accuracy on your specific design to compensate for the shrinkage:

• Achieved density with Epsilon Series: 7.74 over 7.85 g/cm3 (98.59%).
• Shrinkage with Epsilon Series: 19% XY / 24% Z (it depends on the geometry).
• Maximum accuracy achieved with Epsilon Series: up to ±0.09mm XY / ±0.04mm Z.

In the chart below, you can find the differences between 316-L and 17-4PH:

Main properties

Post-processing metal parts

The metal printed pieces can be treated the same way as steel manufactured parts are treated in traditional ways, creating a wide range of possibilities to improve the finish of the piece.

In this article, we explain the different processes you can perform on your pieces to improve the surface quality: https://support.bcn3d.com/knowledge/postprocess-metal-parts

Aluminium frame

• 1x 316L 3Kg BASF spool
• 1x 17-4PH 3Kg BASF spool
• 2x Hotend M
• 1x Magigoo Pro Metal
• 2x Brass Wiper
• Activation code

Q&A

What is the shrinkage % with this material?

With the BCN3D metal printing profile, we have established the shrinkage at 19%XY & 24%Z, meaning that we print more densely than other brands and therefore waste less printing time.

Can the debinding and sintering be done without outsourcing? Can I purchase the equipment and debind and sinter the parts myself?

It is absolutely possible to carry out the Debinding and Sintering steps yourself if you have access to a facility with the correct equipment or are interested in doing debinding and sintering on a scale that justifies the capital equipment. However, the most cost-effective method for the majority of users will be utilizing the network of debinding and sintering service centers prepared to handle the parts.

How much does outsourcing debinding and sintering cost?

40-70€/KG.

Can I use support materials for this filament?

We do not recommend using supports with your Ultrafuse 316L prints. While it is possible to use breakaway and water-soluble supports to help produce Ultrafuse 316L parts, they will not be able to maintain the print’s shape during the sintering process, which will lead to deformity. Using Ultrafuse 316L filament as its own support material is also possible, but would require machining, cutting, or grinding the support off after sintering. Nowadays, BASF is working on a ceramic support, which would work well with our IDEX technology. Another alternative is to remove supports and indicate to apply ceramic spray in the interface before the process prior to sending your parts away to suppliers.

Printed part examples