3D metal printer

14 Articles

Building A Metal 3D Printer With A Laser Welder

February 1, 2026 by 6 Comments

The development of cheaper, more powerful lasers has always been a cause for excitement among hackers, and fiber lasers are no exception. One of the newer tools they’ve enabled is the laser welder, which can be used to weld, cut through metal, or clean off surfaces. Or, as [Cranktown City] demonstrated, you can use one to build a metal 3D printer.

The printer’s built around a 2000-Watt fiber laser welder from Skyfire, and the motion system came from a defunct secondhand 3D printer built by an out-of-business insole printing company. The frame was reinforced with steel, the welding gun was mounted in place of the hotend, and the trigger was replaced with a CNC-controlled switch. It didn’t originally use any specific shielding gas, since the welder was supposed to perform adequately with just compressed air if high weld quality wasn’t essential.

The first few tests were promising, but did reveal quite a few problems. Heat buildup was an early issue which threatened to warp the build plate, and which eventually welded the build plate to the Z-axis gantry. Adding a strong cooling fan and putting a gap between the build plate and the gantry solved this. The wire also kept getting stuck to the build surface, which [Cranktown City] solved by pausing the wire feed and pulling it away from the part when a layer finished. Simply using compressed air led to a weak deposit that cracked easily, and while a nitrogen stream improved the print somewhat, argon shielding gas gave the best results. For his final print, [Cranktown City] made a vase. The layers were a bit crude, but better than most welder-based metal printers, and the system shows some real promise.

We’ve seen a few printers built around welders before, and a few built around lasers, but this seems to be the first to use both.

A bed of metal powder is visible through a green-tinted window. A fused metal pattern, roughly square, is visible, with one corner glowing white and throwing up sparks.

Printing In Metal With DIY SLM

January 3, 2026 by 5 Comments

An accessible 3D printer for metals has been the holy grail of amateur printer builders since at least the beginning of the RepRap project, but as tends to be the case with holy grails, it’s proven stubbornly elusive. If you have the resources to build it, though, it’s possible to replicate the professional approach with a selective laser melting (SLM) printer, such as the one [Travis Mitchell] built (this is a playlist of nine videos, but if you want to see the final results, the last video is embedded below).

Most of the playlist shows the process of physically constructing the machine, with only the last two videos getting into testing. The heart of the printer is a 500 Watt fiber laser and a galvo scan head, which account for most of the cost of the final machine. The print chamber has to be purged of oxygen with shielding gas, so [Travis] minimized the volume to reduce the amount of argon needed. The scan head therefore isn’t located in the chamber, but shines down into it through a window in the chamber’s roof. A set of repurposed industrial servo motors raises and lowers the two pistons which form the build plate and powder dispenser, and another servo drives the recoater blade which smooths on another layer of metal powder after each layer.

As with any 3D printer, getting good first-layer adhesion proved troublesome, since too much power caused the powder to melt and clump together, and too little could result in incomplete fusion. Making sure the laser was in focus improved things significantly, though heat management and consequent warping remained a challenge. The recoater blade was originally made out of printed plastic, with a silicone cord along the edge. Scraping along hot fused metal in the early tests damaged it, so [Travis] replaced it with a stainless steel blade, which gave much more consistent performance. The final results looked extremely promising, though [Travis] notes that there is still room for redesign and improvement.

This printer joins the very few other DIY SLM machines we’ve seen, though there is an amazingly broad range of other creative ideas for homemade metal printers, from electrochemical printers to those that use precise powder placement.

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Printed In Space: 3D-Printed Metal Parts Shown Off After Returning From The ISS

September 8, 2024 by 21 Comments

The European Space Agency (ESA) is showing 3D-printed metal parts made onboard the International Space Station using a printer and materials the agency sent earlier this year.  While 3D printing onboard the ISS is nothing new, the printing of metal parts in space is an important advancement. The agency’s goals are to be able to produce more tools and spares in situ rather than having to rely on resupply missions. An ambitious idea being pitched is to use captured space debris as input as well, which would further decrease the ISS’s dependence on Earth and expensive cargo runs from the bottom of the gravity well.

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CeraMetal Lets You Print Metal, Cheaply And Easily

July 21, 2024 by 27 Comments

3D printing metal has been somewhat of a holy grail for the last decade in the hobby 3DP scene. We’ve seen a number of solutions, including using expensive filaments that incorporate metal into the usual plastic. In parallel, we’ve seen ceramic printers, and paste printers in general, coming into their own. What if you combined the two?

You’d get [Leah Buechly] et al’s CeraMetal process, which is the cheapest and most straightforward metal printing method we’ve seen to date. It all starts off with a custom bronze metal clay, made up of 100 g bronze powder, 0.17 g methyl cellulose, 0.33 g xanthan gum, and 9 g water. The water is fine-tuned to get the right consistency, and then it’s extruded and sintered.

The printer in question is an off-the-shelf ceramic printer that appears to use a pressurized clay feed into an auger, and prints on a linen bed. [Leah] had to write a custom slicer firmware that essentially runs in vase mode but incorporates infill as well, because the stop-start of normal slicers wreaked havoc with clay printing.

The part is then buried in activated carbon for support, and fired in a kiln. The result is a 3D printed bronze part on the cheap; the material cost is essentially just the cost of the metal powder and your effort.

We had never heard of metal clay before, but apparently jewelers have been using it for metals other than just bronze. The Metal Clay Academy, from the references section of the paper, is an amazing resource if you want to recreate this at home.

Paste printers are sounding more and more interesting. Obvious applications include printing chocolate and printing pancakes, but now that we’re talking metal parts with reasonably consistent shrinkage, they’ve got our attention.

Reducing Warping In Metal 3D Prints

April 13, 2022 by 9 Comments

We are used to dealing with warping when printing with thermoplastics like ABS, but metal printers suffer from this problem, too. The University of Michigan has a new technology, SmartScan, that promises to reduce this problem. You can see a video about the technique, below.

The idea is to develop a thermal model of the printed part before laser sintering and then move the laser in such a way that heat doesn’t accumulate. The video shows how engraving metal in the traditional way causes the metal to warp as the laser heats up areas. Using the SmartScan thermal model, they were able to reduce deformation by almost half.

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3D Metal Printer Uses Welding Wire

March 31, 2020 by 45 Comments

If you’ve seen both a fused filament fabrication (FFF) printer and a wire welder, you may have noticed that they work on a similar basic principle. Feedstock is supplied in filament form — aka wire — and melted to deposit on the work piece in order to build up either welds in the case of the welder, or 3D objects in the case of the printer. Of course, there are a number of difficulties that prevent you from simply substituting metal wire for your thermoplastic filament. But, it turns out these difficulties can be overcome with some serious effort. [Dominik Meffert] has done exactly this with his wire 3D printer project.

Extruder cold end using a standard feeder roller

For his filament, [Dominik] chose standard welding wire, and has also experimented with stainless steel and flux-cored wires. Initially, he used a normal toothed gear as the mechanism in the stepper-driven cold end of his Bowden-tube extrusion mechanism, but found a standard wire feeder wheel from a welder worked better. This pinch-drive feeds the wire through a Bowden tube to the hot end.

In thermoplastic 3D printers, the material is melted in a chamber inside the hotend, then extruded through a nozzle to be deposited. Instead of trying to duplicate this arrangement for the metal wire, [Dominik] used a modified microwave oven transformer (MOT) to generate the low-voltage/high-amperage required to heat the wire restively. The heating is controlled through a phase-fired rectifier power controller that modulates the power on the input of the transformer. Conveniently, this controller is connected to the cooling fan output of the 3D printer board, allowing any standard slicer software to generate g-code for the metal printer.

To allow the wire to heat and melt, there must be a complete circuit from the transformer secondary. A standard welding nozzle matching the wire diameter is used as the electrode on the hot end, while a metal build plate serves as the other electrode. As you can imagine, getting the build plate — and the first layer — right is quite tricky, even more so than with plastic printers. In this case, added complications involve the fact that the printed object must maintain good electrical continuity with the plate, must not end up solidly welded down, and the fact that the 1450 °C molten steel tends to warp the plate.

Considering all the issues that have to be solved to make this all work, we are very impressed with [Dominik’s] progress so far! Similar issues were solved years ago for the case of thermoplastic printers by a group of highly-motivated experimenters, and it’s great to see a similar thing starting to happen with metal printing, especially using simple, readily-available materials.

This isn’t the only approach to DIY metal printing, though. We saw one that used electron beam melting (EBM) not too long ago.

Thanks to [Krzysztof] for the tip!

3D Printing In Metal: The Laser And Metal Powder Printers We Saw At IMTS

September 17, 2018 by 24 Comments

Last week I went to the International Manufacturing Technology Show (IMTS) and it was incredible. This is a toy store for machinists and showcases the best of industrial automation. But one of the coolest trends I found at the show are all the techniques used to 3D print in metal. The best part is that many of the huge machines on display are actually running!

It’s probably better to refer to this as additive manufacturing, because the actual methods can be significantly different from your 3D printer. Below you’ll find examples of three different approaches to this process. I had a great interview with a company doing actual 3D printing in metal using a nozzle-based delivery often called cladding. There’s a demo video of powder layer printing using lasers. And a technique that uses binders as an intermediary step toward the final metal part. Let’s take a look!

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