Metal 3D Printing: What You Need to Know Before You Begin

At Formero, we often speak with clients who are excited by the possibilities of Metal 3D printing — but are surprised to learn that it’s a highly specialised process, very different from printing in plastic or traditional manufacturing. This article isn’t designed to scare you away from using Metal 3D printing — it’s about helping you understand the critical factors we need to consider before production begins. With the right knowledge, planning, and partnership, Metal 3D printing can deliver outstanding results. At Formero, we work closely with clients to navigate these complexities and bring their projects to life with confidence.

Designing for Metal 3D Printing

Metal 3D printing unlocks new possibilities that traditional manufacturing can’t match, but it still comes with specific design rules. Parts must be engineered foremost with additive manufacturing in mind to avoid defects caused by stress & warping. Design for Metal 3D Printing should always aim to minimise the need for support structures.

Traditional part designs are rarely suited for Metal 3D Printing without modification. Simply converting an existing design from another manufacturing method to Metal 3D Printing often leads to print failures or results in parts that are neither practical nor cost-effective to produce.

Our in-house experts work alongside customers at the early design stage to ensure parts are optimised for Metal 3D Printing. From wall thickness to overhang angles and support-friendly geometry, we help our clients make smart design decisions that save time and reduce costs later in the project.

Costs associated with Metal 3D Printing

Metal 3D Printing is an advanced technology, and that comes with an upfront investment that can surprise first-time customers. The cost of handling & storing specialised (and often  hazardous) metal powders, powder batch traceability, the high-maintenance nature of Metal 3D Printers, printing in inert filtered Argon atmospheres, and the significant risk of print failures all contribute to the overall price.

But at Formero, we believe in offering value through reliability and expertise. Our experienced team carefully evaluates every project, advising on designs to help reduce potential failure points and avoid costly reprints. When you work with Formero, you’re not just paying for a part — you’re investing in a process backed by proven knowledge, Australian-based support, and strict quality control.

Extensive Post-Processing Requirements

A common misconception is that Metal 3D printed parts emerge from the machine ready for use. In reality, post-processing is a vital stage in the workflow. The post-process stage can be very labourest in terms of time and money. This can include support structure removal, powder removal, stress relieving, heat treatments, CNC machining, grinding, polishing, and surface coating.

Support removal alone can present challenges, especially if your part has internal channels, tubes, or intricate features. Supports lodged in these areas can be difficult or impossible to remove without damaging the part, and additional machining is often required. At a minimum, parts must be removed from the platform using specialised EDM precision cutting processes, as SLM printing produces parts that are welded to the build substrate. 

Surface roughness is another consideration. Metal 3D Printed parts typically require post-processing to achieve the desired surface finish, especially for precision applications, or where fitment into other assemblies is needed. At Formero, we offer a full suite of post-processing services, including machining (EDM & CNC), blasting, tumbling, painting, Cerakote coating, and pressure testing — ensuring your part is not only functional but also finished to the highest standard. We can also offer 3D scanning to check print accuracy, and use the data to compensate for distortion. 

Turnaround Times

Metal 3D printing is a highly iterative process that requires detailed preparation and part-specific strategies. Each part needs custom-designed support structures to ensure stability during printing, and it often takes several design iterations to optimise these supports for strength, print quality, and ease of removal.

After printing, supports must be removed through precision processes such as wire cutting or machining, which adds additional time to the workflow. Combined with the post-processing requirements, these factors can lead to longer and less predictable production timelines, particularly for complex or first-time designs. At Formero, we manage this through clear communication, early-stage design guidance, and realistic project timelines based on our extensive experience.

Testing and Inspection

Due to the critical applications where Metal 3D printed parts are often used, thorough testing and inspection play a key role in the manufacturing process. At Formero, we offer a range of non-destructive and precision testing methods to validate part quality, structural integrity, and dimensional accuracy.

Depending on the application and performance requirements, we can conduct:

• X-Ray Inspection — to assess the internal structure of parts, ensuring there are no hidden voids, inclusions, or other internal defects.
  
• 3D Scanning and Dimensional Reports — to compare the printed part against the original CAD data, enabling the identification of any distortion or dimensional deviation. It is also possible to use  scan data to compensate and improve future builds.
• Low Pressure Leak Testing —  to help identify presence of defects in sealed parts intended for fluid-handling or pressurised applications

Each project is assessed individually to determine the most appropriate testing methods based on the design intent, material, and functional requirements. By offering a full suite of testing services, we help ensure that parts not only meet visual and dimensional standards but also perform reliably under real-world conditions.

Summary

At Formero, Metal 3D Printing isn’t a print-on-demand service — it’s a collaborative process. Our team combines years of hands-on experience with a deep understanding of both the technology and the realities of production. Whether it’s navigating design challenges, post-processing, or part testing, we work with you to bring your project to life with precision and reliability.

Looking for Alternatives? CNC Machining Might Be the Right Solution

While Metal 3D printing offers unique advantages for complex geometries and low to medium production volumes, it’s not always the most practical or cost-effective choice — especially for simpler parts or when tight tolerances and smoother surface finishes are required straight from production.

For many applications, CNC machining remains a highly reliable and efficient alternative. At Formero, we also offer CNC machining services, which can often be a better solution for:

• Parts with straightforward geometries
• Components that demand very fine surface finishes without extensive post-processing
• Designs requiring tight dimensional tolerances
• Medium to high production volumes
• Projects with shorter lead time requirements

Whether you’re exploring Metal 3D printing or CNC machining, Formero’s experienced team can assess your project and recommend the most suitable and economical solution based on your design, application, and performance needs. We’re here to help you turn complex ideas into high-quality, functional parts — the right way.

3D Printing, Knowledge Hub