Metal 3D printing materials at a glance

1. Introduction: The variety of metal powders and wires

In industrial metal 3D printing, the material is the decisive factor for the mechanical properties, thermal resistance and cost of the final component. The days when AM systems could only process a handful of alloys are long gone.

Today, a wide range of certified materials are available - from lightweight aluminum for the automotive sector to high-temperature-resistant superalloys for gas turbines. This guide provides a structured overview of the most important material groups in additive manufacturing.

2. Stainless steels (Stainless Steel)

Stainless steels are the most commonly used materials in metal 3D printing. They offer an excellent combination of strength, ductility and corrosion resistance.

2.1 Austenitic stainless steel (316L / 1.4404)

• Properties: Very good corrosion resistance, easy to weld, biocompatible.
• Applications: Medical technology (implants, surgical instruments), food industry, maritime components.
• Printing process: PBF, DED, WAAM, Binder Jetting.

2.2 Martensitic stainless steel (17-4 PH / 1.4542)

• Properties: Higher strength and hardness than 316L, hardenable by heat treatment.
• Applications: Pump components, devices, heavily stressed mechanical components.

3. Tool Steels

Tool steels are extremely hard and wear-resistant. They are the backbone of additive tool and mold making.

3.1 Hot work steel (H13 / 1.2344)

• Properties: Retains its hardness even at high temperatures.
• Applications: Die-casting molds, forging dies.

3.2 Maraging steel (1.2709)

• Properties: Extremely high strength and toughness after aging (hardening). Very easy to machine before heat treatment.
• Applications: Plastic injection molds with conformal cooling, high-strength drive components in motorsport.

4. Titanium and titanium alloys

Titanium is the premium material for lightweight construction. It combines high mechanical strength with low density and exceptional corrosion resistance.

4.1 Ti6Al4V (Titanium Grade 5)

• Properties: The “workhorse” of titanium alloys. Excellent strength to weight ratio. Difficult to machine conventionally, therefore ideal for AM.
• Applications: Aerospace (turbine housings, structural components), motorsport, medical technology (orthopedic implants).
• Printing process: Mainly PBF, increasingly also WAAM for large components.

5. Nickel-based alloys (superalloys)

In environments where even stainless steel and titanium would melt or fail, nickel alloys are used.

5.1 Inconel 718 and Inconel 625

• Properties: Extreme heat resistance (up to approx. 700°C continuous load), oxidation resistance and creep resistance.
• Applications: Combustion chambers in rocket engines, hot gas parts in stationary gas turbines, turbochargers in motorsports.

6. Aluminum alloys

Aluminum is light, conducts heat well and is cost-effective. It is the preferred material for weight-optimized series components.

6.1 AlSi10Mg

• Properties: A typical casting alloy that can be excellently welded using silicon and magnesium and can therefore also be processed additively.
• Applications: Heat exchangers, lightweight components in the automotive industry, housings.

6.2 Scalmalloy (Al-Mg-Sc)

• Properties: A special high-performance alloy with scandium developed for 3D printing. Offers almost the strength of titanium with the density of aluminum.
• Applications: Robotics, aerospace, high-end motorsport.

7. Copper and copper alloys

For a long time, copper was considered "unprintable" due to its high reflectivity (infrared lasers are rejected). This has now been solved through the introduction of green lasers (e.g. TRUMPF) and improved process parameters.

7.1 Pure copper (Cu) and CuCr1Zr

• Properties: Maximum electrical and thermal conductivity.
• Applications: Induction coils, heat exchangers, components for electric motors (e-mobility), rocket nozzles.