Introduction to the MetalFuse Solution
Raise3D’s MetalFuse offers a full in-house FFF metal printing solution for manufacturers who require the internal production of metal parts for various uses. MetalFuse consists of an indirect metal 3D printing process, and with it, manufacturers can carry out the entire production process from design to printing, to debinding, sintering and to post-processing, all without anything leaving the factory.
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Raise3D MetalFuse (US and other regions; EU)
Raise3D Forge1(US and other regions; EU)
A Simple Process for Users
Raise3D has developed a special edition of its slicing program- ideaMaker for Metal – to either slice or import Gcode files to the FFF metal printer – the Forge1 – in order to 3D print models, much like FFF 3D printers that create objects using thermoplastics. In this case, the 3D printer produces what are called green parts. Once these green parts are created, they can be subject to process called debinding, and are placed in another machine, the D200-E. This results in what are called brown parts, and finally the brown parts are quickly sintered in the sintering machine, the S200-C. Out of this last machine come the final metal parts, in a manner similar to the MIM process.
Specialized Slicing Software – ideaMaker for Metal
ideaMaker for Metal is slicing software specially developed for metal 3D printing.
A special edition of ideaMaker offers templates optimized for this kind of printing, while taking into account the sintering and debinding processes that the 3D-printed parts are subject to after being created with MetalFuse.
This special edition of ideaMaker also features a simpler slicing process:
1) Provides templates for all processes
ideaMaker for Metal provides metal filament templates that were previously validated, and these enable easier slicing.
2) Easy to set shrink compensation
Unlike other FFF printing methods, metal printing requires a debinding and sintering process to obtain the final parts. To ensure that the final part matches the intended size, the size of the green parts can be automatically set in the software to account for a certain amount of print shrinkage. This guarantees that the final size after debinding and sintering will be accurate and suitable for use.
Metal FFF 3D Printer – Forge1
After slicing with ideaMaker for Metal, the next step is to use Raise3D’s metal FFF 3D printer to print green parts.
As previously mentioned, the Forge1 can print green parts using perhaps the most widespread 3D printing technology, Fused Filament Fabrication (FFF), making it highly accessible to on-demand scalable production. The extensively used nature of this technology creates an ecosystem that drives innovation in various industries with multiple end-use applications.
A hybrid filament of metal and POM-based polymers is used to print the green parts. During printing, the POM melts and the metal particles carried within are deposited.
Advantages of green parts printed using the Forge1
- The ability to consistently produce complex parts
- Smooth surface finish
- High accuracy for assembly
- Can reliably handle batch printing
- High strength and resistance to damage
- Compatible with Metal Injection Molding (MIM) process
Raise3D Debinding Machine – D200-E
Green parts printed using the Forge1 need to be debound and sintered by a debinding machine and a sintering machine respectively, to get the final metal parts. The Raise3D D200-E is a catalytic ethanedioic debinding machine specifically created for this effect.
It is used to remove the POM from parts and prepare the metal for sintering. In the presence of oxalic acid in the high-temperature acidic environment created by the machine, the catalyst gas penetrates the green parts and the POM is decomposed and vaporized.
The D200-E has great performance as it has a high debinding rate, which can achieve catalyst penetration speed of over 1mm/h. It can simultaneously process up to 7 trays (70 green parts of a given size) in just 15 hours.
The catalyst, oxalic acid gas, is biodegradable with low toxicity, and the methanal and acidic gas produced in the D200-E will be discharged along with the protective gas (nitrogen, argon, etc.) through the exhaust gas filtration system. In this way, the D200-E is eco-friendly and suitable for an office environment.
Raise3D Sintering Machine – S200-C
After debinding, users get the brown parts, but these parts are very brittle and crispy, they need to be quickly and carefully moved and to a sintering machine, where they will be heated to sintering temperatures.
The Raise3D S200-C is a vacuum sintering machine, designed to carry out the sintering portion of the indirect metal 3D printing process. During the sintering process, the loose debound parts will shrink into dense solid sintered parts.
S200-C can simultaneously process up to 6 trays without at once using the same amount of energy. Additionally，the sintered part’s density after sintering reaches 97%.
Post-Processing – Machining/Finishing
After going through the printing, debinding, and sintering processes, the final metal parts can be put directly into use. However, for a better surface look, or other special assembly requirements, sintered parts can be lightly machined and processed.
In the following case, drilling is used to assist in adjustments that may be needed for assembly, and the hole tolerance is ±0.2mm. In the case illustrated below, with the post-processing, the sintered part’s hole tolerances already meet applicable standards, and the drilled sintered parts will be used directly in a client’s wiring testing line.
Post-processing methods, such as magnetic abrasive finishing, electroplating, polishing, are also frequently used to fulfill manufacturer requirements. In the example illustrated above, magnetic abrasive finishing is adopted to make the surface of the connector inserts smoother, making it safer and easier to handle.
MetalFuse Solution Benefits
1) Cost-effective
MetalFuse solution makes cost-effective metal printing possible, as the lead time and high production difficulties are all reduced. It utilizes the catalytic debinding process, which leads to 60% off in processing time, and an increase of the part’s density of up to 97%.
2) Environmentally Friendly
Compared to other processes, such as CNC and SLM (Selective Laser Melting), MetalFuse saves more energy, is less wasteful, and consequently is more environmentally friendly.
3) High Accessibility
Raise3D MetalFuse solution makes on-demand scalable production highly accessible. It drives production in various industries with multiple end-use applications, and can meet clients’ requirements for batches of end-use metal parts at lower prices, various batch sizes, ensured quality, reduced maintenance costs, etc.
Learn More about:
Raise3D MetalFuse (US and other regions; EU)
Raise3D Forge1(US and other regions; EU)