Metal additive manufacturing is driving industrialization of 3D printing. While hobbyist 3D printers have helped make the technology mainstream, the vast applications of additive manufacturing have led to it being used throughout the industrial sector.
The ability to additively manufacture metal parts has spurred the adoption of this technology in large manufacturing industries like aerospace, defense, and automotive. Similar to other types of 3D printing, metal 3D printers can create complex designs, manufacture high-performance parts, and minimize material waste.
Though this technology first originated in the 1980s, there have been significant innovations and developments in metal additive manufacturing in the last decade. So much so that additive manufacturing (AM) technologies are widely used to create end-use parts, from luxury car components to elements for aircraft to medical implants. 3D-printed metal parts are everywhere, and the market is only going to grow from here.
The Metal AM Market
With a valuation of $4.55 billion in 2024, the metal AM market is already significant and primed for growth. Between 2025 and 2033, the value is expected to increase by ~$15 billion, bringing it to $19.24 billion. This represents a compound annual growth rate of 17.39%.
The demand for complex, lightweight parts is fueling metal AM’s market growth. As manufacturing advances, more companies are seeking innovative technologies to improve operations and products. Metal additive manufacturing can meet the industry’s modern requirements, offering the capability to manufacture better parts with improved performance.
Types of Metal Additive Manufacturing
Most manufacturers know additive manufacturing as a technology that adds layers of material to create a three-dimensional object. This is contrary to traditional methods where material is removed from an object to create a part, also known as subtractive manufacturing.
In metal additive manufacturing, the same process is used by layering metal powders or wires to create components. There are several different types of metal additive manufacturing:
Powder Bed Fusion
Powder bed fusion (PBF) is an additive manufacturing method used to manufacture metal, plastic, and ceramic parts. This process either uses a laser or electron beam as an energy source. The 3D printing chamber of PBF machines is heated to the required temperature, then a thin layer of powder is printed and heated. For metal parts, PBF uses the energy source to melt and solidify the metal particles in the powder. Once the first layer is complete on the powder bed tray, the tray moves down and another layer is added.
Printing supports should be used while additively manufacturing a component with PBF. These supports help prevent distortion of the part while printing, allowing it to achieve the intended shape and properties. Once the part is fully printed and has cooled, these supports must be removed along with any loose metal powder.
Manufacturers looking to produce end-use metal parts are often using PBF printers in their production. PBF is a top choice because this method is good for producing parts with intricate designs and complex geometry. Other benefits of using PBF are the ability to manufacture lightweight parts and reduce material usage.
Parts created with PBF are limited by the size of the plate within a 3D printer and often can’t exceed one meter. Because PBF prints thin layers and is a slower process than mass production, it is used more often for small production runs and customized products.
Directed Energy Deposition
Directed energy deposition (DED) has some similarities to PBF, but the processes are ultimately very different in practice. Manufacturers can use metal powder or metal wire when producing parts with DED technology. Energy sources used in this method of additive manufacturing include laser, electron beam, and plasma.
These 3D printers use a nozzle placed on a multi-axis robotic arm to create parts. The DED printer is fed powder or wire and then the nozzle deposits the metal layer by layer. Unlike PBF, this method is mostly used for repairing products, coating large metal parts, and adding on to existing parts. DED is also faster and ideal for printing a large volume of material, though it is not able to create parts as detailed as those made with PBF.
Since DED is faster, it is often used to create large-scale products, with the ability to manufacture parts that are several meters long. This method of 3D printing excels at repairing large parts and can also work with different powders to join materials, an advantage that gives DED more flexibility in part creation as opposed to PBF.
Binder Jetting
Whereas PBF and DED methods have some similarities, with the major differences being the way the material is deposited and treated by the energy source, binder jetting (BJT) is an entirely different process. Rather than an energy source, this uses a liquid bonding agent to bind the metal material layer by layer.
BJT can create products from multiple materials, such as metals, ceramics, composites, and even sand. BJT printers deposit the liquid binding agent onto powdered metal material, continuing to deposit the agent layer by layer to build an object.
Though most 3D printing processes require parts to go through post-processing before they are considered completed, this is particularly necessary for parts created with BJT. This process creates weaker initial parts that are only held together by the binding agent. In order for the part to properly harden, it has to go through a sintering process after being additively manufactured.
The initial BJT process is known for its speed and lower cost compared to some other metal AM methods, but the required post-processing can sometimes mitigate these benefits.
Material Jetting
Similar to BJT, material jetting (MJT) sprays onto the build platform to create a part. But what is jetted in this process is the build material, rather than the binding agent in the BJT process. MJT sprays tiny droplets of liquid metal to layer material and create products.
Once sprayed, these droplets are solidified using ultraviolet light. An interesting feature of MJT is that it can use separate jets for different materials, allowing it to combine materials into one product, similar to the DED process feature.
MJT printers have a high level of accuracy for matching the build to a product file, and MJT is also a lower-cost option compared to some other methods. However, the drop-by-drop layering process makes the MJT method one of the slower options for metal additive manufacturing.
Material Extrusion (MEX)
The material extrusion (MEX) method is more often used with polymers, but there are some metal 3D printers that use this process. For metals, this process extrudes melted metal wire or rod through a nozzle or similar part to create the 3D printed product layer by layer.
Parts made through the MEX process also have to go through post-processing, including debinding and sintering. MEX 3D printers tend to be a good option for smaller manufacturers, as this type of metal 3D printing has a lower cost barrier to entry. Though MEX technology adoption is predicted to grow, it is currently used mainly for prototyping and small production runs.
Sheet Lamination (SHL)
Sheet lamination (SHL) for metal parts involves layering metal sheets to create a 3D part. These sheets are bonded together either through adhesive or welding. Ultrasonic welding is the most common method for binding metal sheets.
In order to achieve the desired finished pieces, these parts must also go through subtractive manufacturing methods. After all the layers are added, excess material is removed with a laser cutter or CNC machine.
The SHL process offers manufacturers a more cost-effective way to produce prototypes. However, it has more material waste than other metal additive manufacturing processes and is slower due to the additional subtractive manufacturing required.
Vat Photopolymerization
The last main metal additive manufacturing method is vat photopolymerization (VPP). VPP is unlike any other method of metal additive manufacturing. In this process, metal powder is dispersed in liquid resin, which is then exposed to light wavelengths to make it solidify.
With metals, this process usually uses ultraviolet light. After the first layer solidifies, more of the metal powder/resin mixture is added, continuing to build up the layers into a final product. VPP is an expensive process, but also quicker than some other additive manufacturing methods. Some use cases for VPP include prototyping and the manufacture of micro-parts.
Metal AM Market Growth
Several of these metal additive manufacturing methods are continuing to advance. Though the metal AM market has sufficiently moved beyond just prototypes, there is more potential for these technologies to expand into the production of end-use parts.
All of the different metal additive manufacturing methods allow companies to have greater design flexibility, reduce material waste, and have more resilient supply chains compared to traditional manufacturing. These benefits are driving increased adoption of metal additive technologies among manufacturers.
Metal additive manufacturing adoption will continue to be driven by top industries, including automotive, aerospace, and healthcare, while breaking into new industries such as energy to spur further growth. As the cost of this technology becomes less of a barrier, it will also be adopted by smaller manufacturers and niche industries.
If you’re a manufacturer looking to learn more about metal additive manufacturing, connect with technology providers, and explore where the AM market is heading, you should attend RAPID + TCT: North America’s largest additive manufacturing and industrial 3D printing event. Register here.