Aluminum is a popular material for 3D printing because it offers beneficial mechanical properties, including high strength to weight ratio and corrosion resistance. It is particularly well-suited for the aerospace and automotive industries, where lightweight materials are a priority. In addition, aluminum is ideal for reducing the number of parts required to build components, which can reduce assembly time and overall costs.
The use of aluminum in 3D printing has expanded significantly in recent years. It is now used in a broad range of sectors and applications, including industrial manufacturing, motorsport, cycling, energy, and robotics. It is especially well-suited to a range of additive manufacturing processes, including laser powder bed fusion (L-PBF), Direct Metal Laser Sintering (DED), and binder jetting.
Aluminum can be printed with a variety of alloys, each with different characteristics. The most common is 6061 aluminum, which has good tensile strength and hardness. Other popular options include 5052 aluminum, which is stronger and more ductile, and 7075 aluminum, which is the strongest of all the available options.
Xometry’s large format printers support a wide range of these alloys, with the ability to print structures up to 31.5 in x 15.7 in x 19.7 in. The choice of which alloy to use will depend on the requirements of the final part.
There are also a number of alternative processes for printing aluminum, such as filament extrusion and Wire Arc Additive Manufacturing (WAAM). KM Yachtbuilders recently collaborated with MX3D to produce an aluminum keel for a yacht, using WAAM technology and an off-the-shelf aluminium bar.