Metal 3D printing offers manufacturers a faster and more cost-effective way to produce strong, lightweight, and complex parts. With the Markforged Metal X printing system, businesses can replace certain casting and machining processes, consolidate assemblies, reduce material use, and accelerate production.
However, successful metal printing requires more than simply sending a traditional CAD model to the printer. Wall thickness, supports, holes, threads, part orientation, and post-processing must all be considered during the design stage. In this guide, we explore the key design guidelines that can help you improve print quality and get the most from the Markforged Metal X system.
Benefits of Metal 3D Printing with Markforged Metal X
However, for parts where casting or machining production methods would otherwise be used, producing through the Metal X printing system can be 50-90% faster and less expensive. In many cases multiple fastened pieces can be printed as 1 part, reducing assembly and maintenance time. Also, when the standard print settings are used, a printed part will often be 20% lighter than the same geometry produced by other methods.
Metal X Design Guidelines and Best Practices
Something to avoid is printing part features that could be easily purchased, such as shafts, threaded rods, pins, and similar mechanical hardware items. Additionally, the Metal X supports are fully solid and do not break or dissolve like plastic or composite printed supports do. There is a ceramic release layer between the support and the finished part geometry, however, it is still preferable to avoid as much support as reasonable. For external features, this is often accomplished by using 45-degree chamfers or tapers. For horizontal hole-type features, a teardrop or diamond shape will avoid the support that would have been used for a circular or square feature.
As with any production process, there are some recommended minimum wall thicknesses and feature size dimensions that apply to Metal X printed parts. For structural soundness, the wall thickness of features should be 1.5 mm or greater, vertical holes can be as small as 1 mm, and grooves can be as thin as 0.5 mm.
It is quite possible, and in many cases recommended, to print the threads of tapped holes rather than tap them after the sintering process. Vertical threads can successfully print as small as M3 or #5-40, angled or horizontal threads should be M10 or 3/8”-16 and larger.
Post-Processing and Preparing Parts in Eiger
Printed parts can be lightly sanded or smoothed with Scotch-Brite while in the green state condition to improve surface appearance. When using the standard settings, individual feature faces can be post machined 0.5 mm in the X or Y direction and 0.3 mm in Z to achieve specific fit conditions with other parts.
Eiger does have some additional options for adjusting Metal X printing, particularly with regards to supports. However, it is certainly recommended to always use the [Internal View] mode to examine the part slicing in closer detail before sending it to the printer.
Optimize Your Parts for Metal 3D Printing
The Markforged Metal X system makes it possible to produce strong, lightweight metal parts faster and more cost-effectively than many traditional manufacturing methods. However, achieving the best results starts with designing specifically for the printing process.
By minimizing supports, respecting recommended feature sizes, optimizing hole and thread geometry, and reviewing each build in Eiger’s Internal View, manufacturers can improve print quality while reducing material use, machining, assembly, and production time. These design considerations help unlock the full potential of metal 3D printing for applications such as robotic grippers, tooling components, motor mounts, and powertrain parts.
Contact the Solidxperts team to learn how Markforged Metal X can support your metal part production and help you identify the best applications for your business.
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