Metal 3D Printing (SLM)

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Metal 3D Printing Service

Through industry partners, Formero offers state-of-the-art 3D Metal Printing services utilising Selective Laser Melting (SLM) technology. This advanced manufacturing process allows us to create complex and highly precise metal parts. We understand that 3D printing metal is often difficult, expensive, and slow, so we approach each project with meticulous attention to detail and a commitment to delivering the highest quality results.

How SLM Printing Works

Selective Laser Melting (SLM) is an additive manufacturing process that uses a high-powered laser to melt and fuse metallic powders layer by layer. The process starts with a digital 3D model, which is sliced into thin layers. The laser selectively melts the powder according to the digital design, building the part layer by layer from the bottom up. This method allows for the creation of intricate geometries that would be impossible to achieve with traditional manufacturing techniques.

Advantages of 3D Metal Printing

Design Freedom: Create complex geometries not achievable with conventional manufacturing, including internal passages that casting or CNC Machining cannot produce.
Customisation: Produce parts tailored to specific needs, including unique, one-of-a-kind components.
Material Efficiency: Minimise waste by using only the material required to build the part.
Difficult-to-Form Alloys: Work with metals that are hard to machine or cast conventionally, including Titanium and Inconel.
Fine Features and Thin Walls: Achieve features and walls below 0.5mm, with sharp points potentially printable.
High-Temperature Performance: Suitable for applications requiring strong thermal resistance.
Thermal and Electrical Conductivity: Produce parts with excellent conductivity properties.
High Density and Purity: SLM produces parts without binders, sintering, or firing, resulting in superior material integrity.
Near-Net Shape: Parts require minimal post-processing, making SLM a strong alternative to casting.

Disadvantages of 3D Metal Printing

High Costs: Metal powders and advanced equipment make this one of the more expensive manufacturing processes.
Slower Production Speed: Metal 3D printing is slower and less predictable than most manufacturing processes, making timeframe estimation challenging. Every design requires custom support structures to achieve quality results, and these often take multiple iterations to optimise. Removing them adds further time, typically requiring secondary operations such as wire cutting or machining.
Post-Processing Requirements: Metal 3D printing involves more labour-intensive post-processing than plastic 3D printing.
Material Limitations: Not all metals are suitable, and material properties can vary between builds.
Design Constraints: Parts must be carefully designed for SLM. Unlike plastic 3D printing, support material cannot compensate for poor geometry decisions.
Surface Finish Variability: Finish quality depends on build angle and other process factors.

Ensuring High-Quality Results

To ensure the highest quality results, Formero implements rigorous testing procedures for all 3D Printed metal parts. We collaborate with Industry Leading Partners to offer comprehensive testing services, including:

Tensile Testing: Evaluates the material’s strength and ductility by pulling the sample until it breaks, providing essential data on the material’s behaviour under stress.
Non-Destructive Testing (NDT): Assesses the integrity of the part without causing damage, using methods such as ultrasonic, radiographic, and magnetic particle testing to detect any internal defects or inconsistencies.
X-Ray Testing: Uses X-rays to inspect the internal structure of the part, identifying potential flaws that are not visible to the naked eye.
These stringent quality control measures ensure that every part we produce is free from defects and meets the highest industry standards.

Materials We Offer

Formero provides a selection of high-quality metal materials for 3D printing, including:

Aluminium: Known for its lightweight and excellent thermal conductivity, Aluminum is ideal for applications requiring strength without added weight.
Titanium: Offers superior strength-to-weight ratio and excellent corrosion resistance, making it suitable for aerospace, medical, and high-performance engineering applications.
Stainless Steel: Renowned for its strength, durability, and resistance to corrosion and high temperatures, Stainless Steel is perfect for a wide range of industrial and consumer products.

We are also open to discussing other metal materials during the consultation stage to meet specific project requirements.