With resin and polymer 3D printing solutions in its portfolio, 3D printer manufacturer Zortrax already had a wide range of solutions to meet different production needs. It now completes its portfolio with a Full Metal Package that would enable its users to explore metal 3D printing applications.
Compatible with its Zortrax Endureal 3D printer, the Full Metal Package includes the BASF materials 17-4 PH and 316L, a low-melt VICTREX PAEK AM™ 200 as well as other essentials for an easy start.
“When using metallic powder filaments for metal 3D printing, micro-cracks or brittle spots on the models are the common issues users struggle with. The reason is usually the improper inner structure, which prevents the target items from preserving all the properties desired for metal. Being aware of that, we focused on creating the solution, ensuring that models have the right structure, allowing them to be applied just like regular steel. We succeeded, as it is obtained on Zortrax Endureal during the very printing process. Moreover, our new Zortrax Full Metal Packages come together with, amongst other elements, high quality metal-polymer filaments by BASF Forward AM, and a voucher for professional post-processing in Elnik Systems GmbH, where the 3D prints undergo proprietary catalytic debinding and sintering processes,” says Michał Siemaszko, Head of Research and Development Department at Zortrax.
Key specifications about the materials and the process
While the BASF materials 17-4 PH and 316L have already been seen in metal packages from some FDM 3D printer manufacturers, the low-melt VICTREX PAEK AM™ 200 is a material we didn’t hear much about.
It is a filament, which has a lower melting point than PEEK and can be extruded in lower temperatures. It belongs to the same thermoplastics’ family as Z-PEEK. The most important features of VICTREX AM™ 200 FIL include low viscosity, assuring easier flow through the nozzle, slow crystallization rate facilitating strong interlayer bonding that improves tensile strength along the Z-axis, high dimensional stability, and minimized warpage. VICTREX AM™ 200 FIL is a perfect fit every time, when the manufactured models require chemical resistance, significant mechanical strength as well as a capability to 3D print with soluble support, and to withstand extreme temperatures. The polymer combines all the advantages of PEEK and adds such benefits as higher strength values, especially in the Z-axis, less shrink and warpage and soluble support compatibility. Moreover, it features a wider process window, thanks to which outcomes and design freedom will often be improved while working with PAEK.
As a reminder, the BASF Ultrafuse® 316L is a filament composed of 80% 316L stainless steel and 20% polymer. It is a surgical-grade stainless steel that contains over 10% of chromium.
This chemical element, while in contact with oxygen, causes a thin coating layer to form on the surface of the model, protecting it from corrosion. The parts 3D printed with BASF Ultrafuse® 316L have up to 561 MPa tensile strength, 251 MPa yield strength, up to 53% elongation at break, and have non-magnetic microstructure. All these features make this metal-polymer filament perfect for 3D printing complex end-use parts, automotive parts, medical equipment, chemical pipes or valves, elements of tools and fixtures as well as various functional prototypes.
The BASF Ultrafuse® 17-4 PH on the other hand is an industrial composite filament, comprising 80% of 17-4 hardened steel and 20% of polymer content. Models, 3D printed with this filament, are characterized by up to 1004 MPa tensile strength, 764 MPa yield strength, up to 4% elongation at break, and have magnetic microstructure. BASF Ultrafuse® 17-4 PH can be successfully used for all the elements, requiring significant hardness, chemical pipes or valves, strong metal end-use parts, medical equipment, automotive parts, elements of tools and fixtures, and functional prototypes.
In each of the Full Metal package, the users will find: BASF Ultrafuse® Support Layer, a dedicated support material, ensuring the desired geometry of the printed parts during the 3D printing and post-processing stages, Magigoo® Pro Metal adhesive to provide reliable adhesion during printing and the easy removal of the printed part, an extra hotend module with brass nozzles for Zortrax Endureal, and a voucher for professional post-processing in Elnik company (BASF’s trusted partner in Germany), where 3D prints undergo crucial sintering and debinding processes to achieve all the properties of steel.
As far as the process is concerned, metal 3D printing technology developed by BASF Forward AM is an efficient manufacturing method, which involves using metal-polymer filaments to produce industrial-grade, stainless steel components. Compared to traditional production technologies, such as CNC machining or Metal Injection Molding, metal 3D printing ensures more flexibility of design, and most importantly, is much more affordable. While 3D printing with metallic powder filaments, however, it is vital to use a quality, reliable 3D printer, capable of processing them properly. It is also crucial to take care of proper post-processing. Considering this, Zortrax specialists have created unique metal packages, which encompass it all, the company concludes.
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