Metal 3D Printing Cost: Dispelling The Confusion

Metal 3D printing is a revolutionary process of constructing parts.  These parts can bring about a radical change in design concepts, but the cost is a huge factor in its favor. Most design professionals experience the metal 3d printing cost as complex and sometimes surprisingly high, which complicates the budgeting processes. Nonetheless, knowing what makes cost, materials, technology, and post-processing, makes metal 3D printing an innovative, cost-effective, and beneficial manufacturing solution.

The metal 3d printing process is costly and prices may differ depending on the materials used, part geometry, and intended use. Generally, the costs vary from $50 to several thousand dollars for a single part. Thus, by selecting the right materials and design changes you can regulate 3D printing costs. 

By understanding these cost drivers, you can make better decisions in the metal 3D printing business. Now let’s discuss how various aspects affect the metal 3d printing cost to maximize your return on investment(ROI).

Fixed Cost Determinants of Metal 3D Printed Parts

Compared to methods, like casting or molding, metal 3D printing offers a clear advantage for developers, and lower upfront costs. For most applications, avoiding custom tooling saves time and money.

Optimization of 3D Design in Additive Manufacturing

The redesigned bottle opener for additive manufacturing is an example of how effectively 3D printing uses support structures. Even simple tools such as cost calculators help estimate the cost of desktop printers, but industrial printers require more significant capital outlay and infrastructural requirements.

Industrial 3D Printer Installation Costs

Industrial 3D printer

Industrial printers are more expensive to set up than desktop ones. Some of the primary factors that may affect these costs include; power, material, build volume, and validation. Normally, it costs from $20,000 for the small photopolymer model to millions for the large metal printers. Some operational costs may be material recycling, inert gases, lasers, part washers, etc all necessary to ensure safety.

Essential Setup for Industrial 3D Printing

Industrial 3D printing requires maintenance, accurate calibration, and most importantly skilled technicians. Moreover, You can expect some setup and testing periods before reaching full production.

Major Cost Drivers in Metal 3D Printing

The two largest costs in metal 3D printing are associated with time to machine, 3d printing plastic costs, and the cost of labor/human resources. Unlike most other manufacturing technologies, materials are the secondary cost drivers in DMLS printing. Resolution affects cost too; the higher the number of layers, the longer the construction time required.

Essential Post Processing Expenses in 3D Printing

In nearly all cases, post-processing of 3D-printed parts is necessary. Some intervention is required to remove supports and any leftover materials from the construction process. Post-processing workflows vary by technology, and therefore, costs can increase. Support structures typically bond to both the part and the build platform. Therefore, metal 3D-printed parts usually undergo stress relief before the supports are removed. 

Comparative Costs of Metal 3D Printing Techniques

Here’s a table outlining some metal 3D printing technologies along with their approximate cost ranges:

Note: Metal 3d printing cost can vary significantly based on the part complexity, production volume, and intended 3d printing materials.

Is Metal 3D Printing Cheaper than CNC Machining?

3D printing Vs. CNC machining

The cost comparison between metal  3d printing vs CNC machining can be done in part design, volume, and material. Metal 3D printing is typically more economical when complex geometry is required in low production volumes. The geometries that are not easily machined are internal channels, lattice structures, and so on, while with 3D printing, the waste of expensive metals like titanium is also decreased. CNC machining is usually more efficient in high-volume production where the cost of the machines is justified. The reason? CNC can work with basic geometry fewer operations of secondary operations and lower cost of setup.

Metal 3D printing needs gentle handling for powders and regular cleaning for the printer increasing its costs. Whether precision and smooth surface finish are important factors, CNC generally stands out due to its capability in this aspect. In general, 3D printing can be more effective in the production of intricate and varied components, whereas CNC machining is preferable for high repeatability of simple geometries.

Tips to Reduce Metal 3D Printing Costs

Here are common techniques to reduce metal 3d printing prices. 

1. Optimize Part Design for Efficiency

3D printing design specifically focuses on the reduction of supports and the post-process. Lessening of overhangs and channelization further reduces the amount of material used, construction time, and labor costs.

2. Select Appropriate Material Powder and 3D Printer

Metal powder for 3D 3rinter

Selecting the right material and machine on the assembly line also reduces the time and money used in production. For example, aluminum is lighter, stronger, and cheaper than titanium. Avoid buying machines that don’t match your material and precision requirements.

3. Adjust Layer Height for Balanced Quality

Choosing the correct layer height saves time and material expenses. Higher layers reduce the time taken to print while still being able to meet most of the tolerance and detail demands. For basic parts, a standard definition rating is often adequate.

4. Consolidate Parts on Build Platform

Having multiple parts on one build volume is beneficial for the machine. Bracing components reduces support material and time taken to print hence reducing the cost.

5. Limit Post Processing to Essential Steps

The post-processing should only be done with the necessary finishes. A simple surface finish is often sufficient for many applications. This approach helps keep 3D printing metal costs low, especially for functional components. 

6. Routine checkup for the 3D printers

3D printing inspection 

3D printing reduces the risk of having to stop the print job entirely. This helps prevent costly delays and disruptions. Maintenance reduces repair expenses, optimizes productivity, and eliminates poor prints that are costly.

What Are the Costs of 3D Metal Materials?

The prices of metal filament differ greatly, from $250 to $475 per kilogram of stainless steel. Copper’s price is approximately $ 121/ kg while that of titanium is approximately $ 832/ kg. These material costs can add up quickly. In a short time, they may even reach the price of the 3D printer itself, impacting low-cost 3D printing efforts.

Metals powders and wires are part of a broader category in 3D printing technologies. When choosing a metal 3D printer, ask whether it can use standard metal materials that are used in metal injection molding or welding. Many manufacturers can benefit from material consistency in both traditional and additive processes.

Metal powders are multifunctional, so their prices vary. As for stainless steel 3d printing powder, it is expected to be priced between $90 and $120 per kilogram. Meanwhile, Titanium 3d printing costs between $450 and $600 per kilogram. Many applications, especially aerospace, require the use of certain powders for 3D printing among others. The majority of metal 3D printers can work only with these specific types of material.

What Is the Hourly Cost of 3D Printing?

There are several things taken into consideration when determining the metal 3d printing cost for an hour. These may include electricity cost, material cost, cost of labor, maintenance, and other items as may be required such as support materials.

Evaluating these elements allows for making precise estimations of the 3d printing metal parts costs of one hour. Use the following formula for a straightforward calculation:

Total cost per hour = Cost of Electricity + Cost of materials used + Consumable wear and tear + Labour cost + Depreciation on Printer + Overhead expenses

To determine the electricity cost, use this formula:

Printer Electricity Cost = (Printer Power Consumption in KW) x (Printing Hours) x (Rate per unit kWh)

For material costs, apply this formula:

Material Cost = (Cost of the Specific Material) x (Quantity of the Specific Material Consumed per Hour)

For instance, a local DIY 3D printing service provider might cost a minimum of $1 to a maximum of $3 per hour. This price contains the cost of the filament and all the fixed expenses.

ProleanTech Custom Metal 3D Printing Services

Prolean Tech offers custom 3d printing solutions. From digital design to functional parts, We utilize the latest SLM 3D printing technology for direct processing. Our competent support group is available to solve your project-related issues promptly and adequately.

Apart from metal printing, We provide innovative post-processing services using our 3D Plus™ technology. It facilitates the achievement of the best quality of the finished components. By employing the Selective Laser melting technology, we produce parts with complex shapes and high mechanical performance. This approach is especially ideal for the production of equipment in aerospace, medical, and manufacturing 3d printing automotive parts as it reduces the dimensional changes that might affect the quality of the final output on the production line.

General FAQs About Metal 3d Printing Cost

Q1. What are the main drivers of metal 3D printing prices?

Main cost drivers include; material cost, time spent by machines, labor cost, post-processing requirements, and setup costs affect the total cost of 3d printing.

Q2. How does the material type influence the cost of metal 3D printing?

Some metals are cheaper than others per kilogram. For instance, titanium costs much more than aluminium 3d printing costs, resulting in a high total project cost.

Q3. Why do larger 3D printed parts lead to higher costs and waste?

Larger parts usually take more material to build and consequently, more time to construct which will lead to a higher 3d printing price. Further waste can be costly for a business. Therefore, it’s essential to minimize waste through efficient design.

Q4. How do high-resolution prints cost more?

Because they require more layers thus more time to build and are relatively expensive to accomplish high-resolution prints. Cost and quality are always an issue in design choices.

Q5. Are there hidden costs in metal 3D printing?

Yes, potential hidden costs include post-processing, machine maintenance, material losses, and other operational costs that should also be included in the budget.

Q6. How does the operational cost differ from one type of printer to the other?

The cost of operation varies with the type of printer due to differences in power consumption, frequency of maintenance, and how it handles materials.

Q7. How can companies use cost estimation for metal 3D printing projects?

Material costs, equipment time, labor costs, and other incidental costs should be considered to make a realistic cost estimate for 3d printing metal parts.