Metal powder is the most commonly used material for additive manufacturing with metal. However, alternative materials are also gaining ground, including metal wire. Various directed energy deposition (DED) printing methods with a wide range of energy sources are used to print metal wire.
This is according to research by IDTechEx. The research firm points out that that metal wire offers significant advantages for additive manufacturing. For instance, this material has long been used in the welding industry, material costs are relatively low and the production process is suitable for upscaling.
Advantages over powdered material
Even compared to powder-based 3D printers, using metal wire offers advantages. For instance, unlike powder, metal wire cannot dust, the material can be printed significantly faster and it is possible to place print heads on industrial robotic arms, which is also known as robotic 3D printing. IDTechEx does note, however, that developments in powder-based 3D printers are not standing still and these printers too can print faster and faster. Metal binder jetting is the most common technology here for high-volume applications.
However, metal wire also has disadvantages. The biggest disadvantage, according to research, is that printed objects in many cases require post-processing. This negates some of the advantages of the DED method such as production speed.
Divergent applications
Nevertheless, metal wire has diverse applications. The material is already being used in some large-scale projects. One example is the production of certain structural components of the Boeing 787 by Norsk Titanium. The use of the printing method here provides significant cost advantages.
IDTechEx also points to confusion that has arisen over metal wire-based 3D printers. Despite the fact that the printing techniques used by many parties are similar, many names are used for these. The main reason for this is that many new entrants to the market claim to have developed a new printing technique, effectively sticking a new name on the DED printing method. For instance, these processes all use metal wire, which is passed through the printer and cured using an energy source. Notably, this energy source varies and can include an electron beam, laser, plasma or welding spark. The research firm therefore categorises these printers all as metal wire-based printers.
Economically viable applications
The research firm expects that we are only at the beginning of the development of metal wire-based DED printing processes. Rather than competing with powder-based 3D printers or other printing processes, the printing technology is expected to have new applications. A large number of new players from different backgrounds are entering the market for these printers. Since it takes time to find economically viable applications, IDTechEx expects that many of these players are going to struggle to survive. The current economic climate due to the COVID-19 pandemic is also contributing to this.
Further information on the research report is available here.
Market grows rapidly
In August, the research firm also released a research report on 3D printers for metal. This showed, among other things, that the market for additive manufacturing in metal is developing at a rapid pace. Not only do such 3D printers print faster and faster, they can also make larger and larger prints and more and more 3D printers are available. An important development is the introduction of relatively cheap printers, available for less than $100,000. This makes 3D metal printing accessible to more companies. Also in this research, IDTechEx notes that finding economically viable applications is difficult due to the high price tag of 3D printers for metal. More information on this research is available here.
Author: Wouter Hoeffnagel
