ISO 9001 & AS9100 Certified Metal 3D Printing Facility
Metal 3D Printing Service
When you need complex metal parts that CNC machining cannot produce economically, or tooling lead times make casting impractical, metal 3D printing is often the only viable path. A metal 3D printing service transforms CAD data directly into fully dense parts in titanium, aluminum, stainless steel, and nickel superalloys — without molds, dies, or material waste.
At Baetro, our metal 3D printing service combines DMLS and SLM technologies with in-house post-processing. We produce parts at >99.5% density with material properties that meet aerospace and medical standards. Whether you need one titanium prototype for fit verification or fifty Inconel brackets for a pilot production run, there is no minimum order and no tooling investment.
>99.5%
Part density
5–10 days
Standard lead time
Ti / Al / SS
Metal materials
MOQ 1
Prototype to production
Metal 3D Printing Fundamentals
What Is Metal 3D Printing?
Metal 3D printing — also called metal additive manufacturing — builds parts by fusing metal powder layer by layer using a high-energy source. A laser or electron beam melts powder particles according to cross-sectional data from a 3D CAD model, creating a solid metal part with internal geometries that would be impossible to machine or cast.
The most common technologies are laser powder bed fusion (DMLS and SLM), binder jetting, and directed energy deposition. For product engineers and procurement managers, the key distinction is this: metal 3D printing eliminates tooling, reduces material waste, and compresses lead times from months to days for complex geometries.
Layer-by-Layer Fusion
Laser or electron beam melts metal powder precisely
Complex Internal Geometries
Cooling channels, lattice structures, and topology-optimized designs
Zero Tooling
No molds, dies, or castings required
>99.5% Density
Fully dense parts meeting aerospace and medical standards
Additive Manufacturing for Metal
Eliminates tooling, reduces material waste, and compresses lead times from months to days for complex geometries.
Metal 3D Printing Capabilities
Our Metal 3D Printing Technologies
From DMLS and SLM to binder jetting, Baetro offers a range of metal 3D printing technologies to match your application requirements for density, volume, and cost.
DMLS
DMLS (Direct Metal Laser Sintering)
DMLS uses a high-powered laser to sinter metal powder into a solid part. The laser heats particles to the point where they bond without fully liquefying the entire powder bed. Modern DMLS systems achieve 95–99% density, with some platforms reaching near-full density depending on material and parameters.
- Best for: prototypes and R&D iterations, complex alloy blends, medium production runs (10–500 parts), parts where slight porosity is acceptable or addressable through HIP
- Materials available: Ti-6Al-4V, AlSi10Mg, 316L, 17-4 PH, Inconel 718, CoCr
SLM
SLM (Selective Laser Melting)
SLM uses a laser at higher energy density to fully melt metal powder into a homogeneous molten pool. As the pool solidifies, it forms a dense, uniform microstructure. SLM consistently achieves >99.5% density and delivers mechanical properties that meet or exceed wrought material standards.
- Best for: aerospace structural components under load, medical implants requiring full density, fatigue-critical parts, applications requiring certified material properties
- Materials available: Ti-6Al-4V, AlSi10Mg, 316L, Inconel 718
Binder Jetting
Binder Jetting (for Volume Production)
Binder jetting deposits a liquid binding agent onto metal powder to form a "green" part. The part is then transferred to a furnace for debinding and sintering. This two-stage process is significantly faster than laser-based methods and offers lower per-part cost at production volumes.
- Best for: high-volume production of small-to-medium parts, tooling inserts and fixtures, non-critical components where slight porosity is acceptable, applications where cost per part matters more than maximum density
- Materials available: Stainless steels, tool steels (expanding to copper and nickel alloys)
Cost Considerations
Metal 3D Printing Cost Factors
Understanding what drives cost helps you make informed design and material decisions.
Material Selection
Titanium and Inconel powders cost $300–$1,150+ per kilogram. Stainless steel and aluminum are $60–$115 per kilogram. Material typically represents 10–30% of total part cost.
Part Geometry
Tall parts require more recoating cycles. Complex internal channels increase laser path length. Extensive support structures add material and post-processing time.
Technology Choice
SLM generally costs more than DMLS due to higher energy density and slower build speeds. Binder jetting is the most economical for high-volume production.
Post-Processing
Heat treatment is standard and included. HIP, CNC finishing, and polishing add cost but are often necessary for end-use applications.
Order Quantity
While metal AM has no tooling cost, nesting multiple parts on a single build plate reduces per-part cost by 20–40%.
Quality Requirements
AS9100, ISO 13485, and ITAR-certified production adds documentation and inspection overhead.
Material Library
Metal 3D Printing Materials
We offer precision metal 3D printing in titanium, aluminum, stainless steel, Inconel, and cobalt chrome alloys. Each material is selected for specific mechanical, thermal, and environmental requirements.
Titanium & Aluminum
Ti-6Al-4V (Grade 5): Tensile strength 993–1,055 MPa, yield 855–951 MPa, elongation 15–18%. Exceptional strength-to-weight ratio with biocompatibility and corrosion resistance. Ideal for aerospace brackets, medical implants, and motorsport components.
AlSi10Mg: Tensile strength 268–345 MPa, yield 180–228 MPa, elongation 8–15%. Excellent balance of low weight, thermal conductivity, and printability. Common for lightweight structural components, heat exchangers, and automotive housings.
Stainless Steel & Superalloys
316L: Tensile strength 565–586 MPa, yield 379–386 MPa, elongation 75–78%. Workhorse corrosion-resistant alloy with high ductility and acid resistance. Used for food processing, pharmaceutical, marine, and chemical applications.
17-4 PH: Tensile strength 1,365–1,372 MPa (aged H900), yield 1,227–1,234 MPa, elongation 13%. Precipitation-hardened stainless steel delivering very high strength after heat treatment. For aerospace, oil and gas, pumps, and valves.
Inconel 718: Retains strength above 700°C. Nickel-chromium superalloy for gas turbine blades, rocket engines, and nuclear hardware.
Cobalt Chrome Co28Cr6Mo: Tensile strength 1,213–1,255 MPa. Exceptional wear resistance and biocompatibility for dental frameworks and orthopedic implants.
Technical Specifications
Metal 3D Printing Specifications
Understanding the technical capabilities of our metal 3D printing service helps you design parts that print successfully and meet your performance requirements.
| Specification | DMLS | SLM | Binder Jetting |
|---|---|---|---|
| Layer thickness | 20–60 μm | 20–40 μm | 50–100 μm |
| Tolerance | ±0.1–0.3 mm | ±0.05–0.1 mm | ±0.2–0.5 mm |
| Minimum feature size | 0.3–0.5 mm | 0.2–0.3 mm | 0.5–1.0 mm |
| Minimum wall thickness | 0.3–0.5 mm | 0.3 mm | 1.0–2.0 mm |
| Build volume | Up to 400 × 400 × 500 mm | Up to 280 × 280 × 350 mm | Up to 430 × 320 × 200 mm |
| Surface roughness (as-printed) | Ra 10–20 μm | Ra 5–10 μm | Ra 6–15 μm |
| Density | 95–99% | >99.5% | 95–99% |
Note on tolerances: While metal 3D printing achieves impressive accuracy, critical dimensions often benefit from precision CNC machining as a secondary operation. Our hybrid workflow prints near-net shapes and then machines critical features to tighter tolerances.
Process Comparison
Metal 3D Printing vs. CNC Machining vs. Casting
Choosing the right manufacturing process depends on part complexity, volume, tolerance requirements, and timeline.
Comparison Table
| Factor | Metal 3D Printing | CNC Machining | Casting |
|---|---|---|---|
| Tooling cost | None | Minimal (fixtures) | High (molds/dies) |
| Minimum order | 1 part | 1 part | 100–1,000+ parts |
| Lead time | 5–10 days | 3–7 days | 4–12 weeks |
| Complex geometries | Excellent | Limited | Moderate |
| Internal channels | Standard | Very difficult | Difficult |
| Tolerances | ±0.1–0.3 mm | ±0.005" | ±0.5–1.0 mm |
| Surface finish | Ra 5–20 μm | Ra 0.8–3.2 μm | Ra 3.2–12.5 μm |
| Material range | Ti, Al, SS, Inconel, CoCr | Very wide | Wide |
| Per-part cost (low volume) | $150–500+ | $50–200 | N/A |
| Per-part cost (high volume) | $50–150 | $20–50 | $5–20 |
Decision Guide
- Choose metal 3D printing: Complex geometries, no tooling budget, small batches (1–100 parts), titanium or Inconel parts that are difficult to machine.
- Choose CNC machining: Simple geometries, tightest tolerances, smoothest surfaces, or very large parts.
- Choose casting: High volumes (1,000+), simple to moderate geometries, lowest per-part cost.
Our CNC machining services complement metal AM perfectly — we print near-net shapes and finish critical features on CNC equipment.
Design Guidelines
Design Guidelines for Metal 3D Printing
Designing for metal additive manufacturing requires understanding both the capabilities and constraints of the process.
Wall Thickness
Minimum wall thickness is 0.3 mm for DMLS/SLM and 1.0 mm for binder jetting. Walls below these limits may not fully fuse or may warp during cool-down.
Overhangs and Supports
Overhangs steeper than 45° require support structures. These supports add material, build time, and post-processing effort. Where possible, design self-supporting angles or plan for support removal in your timeline.
Holes and Threads
Printed holes are typically 0.2–0.3 mm undersized to allow for post-machining or tapping. For precision threads, we recommend designing holes that will be drilled and tapped after printing rather than printing threads directly.
Internal Channels
One of the greatest advantages of metal 3D printing is the ability to create conformal cooling channels, lattice structures, and complex internal geometries. These features are fully supported by surrounding powder and require no additional design compromises.
Applications
Industries We Serve with Metal 3D Printing
Metal 3D printing delivers complex geometries, lightweight structures, and patient-specific components across aerospace, medical, automotive, and energy sectors.
Industry
Aerospace & Defense
Lightweight titanium brackets, Inconel turbine components, and complex ducting with 30–50% weight reduction.
Industry
Medical & Dental
Patient-specific Ti-6Al-4V implants and CoCr dental frameworks with porous structures for osseointegration.
Industry
Automotive
Rapid iteration of intake manifolds and lightweight components. Conformal cooling improves thermal performance 20–40%.
Industry
Energy & Industrial
Inconel heat exchangers and stainless steel pump impellers for extreme temperatures and corrosive environments.
Post-Processing
Post-Processing for Metal 3D Printed Parts
As-printed metal parts require several post-processing steps before they are ready for use. Our metal 3D printing service includes all standard post-processing in-house.
Heat Treatment
All metal AM parts receive stress relief heat treatment to minimize residual stresses from the thermal cycling of printing. Additional treatments include:
- Solution annealing: For stainless steels; improves ductility and uniformity
- Aging (H900): For 17-4 PH; increases hardness to 42 HRC
- Solution and aging per AMS 5663: For Inconel 718; boosts temperature resistance and strength
Hot Isostatic Pressing (HIP)
HIP combines high temperature (~1,093°C) and high pressure (15,000 psi) to eliminate any remaining internal porosity. This process is recommended for:
- Aerospace structural components under cyclic loading
- Medical implants requiring maximum fatigue resistance
- Parts requiring X-ray or CT inspection certification
HIP adds 2–3 days to lead time and is quoted separately.
CNC Finishing
Many metal AM parts benefit from CNC machining to achieve tight tolerances on critical features. Our hybrid workflow handles this seamlessly:
- Mating surfaces: Machined to ±0.005" or better
- Threads: Holes drilled and tapped to standard specifications
- Sealing surfaces: Machined for gasket or O-ring interfaces
- Polishing: Surface finish down to Ra <0.4 μm for cosmetic or fluid-contact parts
Why Choose Baetro
Why Choose Baetro for Metal 3D Printing?
We have covered the technology. Here is why engineers and procurement managers choose Baetro for metal 3D printing over other service providers.
Multi-Technology Capability
We offer DMLS, SLM, and binder jetting — not just one process. Our engineers recommend the right technology based on your material, geometry, and volume requirements.
Full Material Range
Ti-6Al-4V, AlSi10Mg, 316L, 17-4 PH, Inconel 718, and CoCr. Full mill certificates and material traceability included.
Hybrid Manufacturing
Print near-net shape on our metal AM systems, then machine critical features on our CNC equipment. One supplier, one purchase order, one timeline.
In-House Post-Processing
Heat treatment, HIP, CNC finishing, bead blasting, and polishing are all done in-house. Parts arrive finished and ready for assembly.
No Minimum Order Quantity
Need one prototype to validate a design? Order one. Need fifty parts for a pilot run? Same process, same quality.
5–10 Day Standard Lead Times
Metal AM parts ship in 5–10 days standard. Expedited options are available for urgent prototypes.
FAQ
Frequently Asked Questions
Answers to common questions about metal 3D printing technologies, materials, costs, strength, and post-processing.
What is the difference between DMLS and SLM?
DMLS sinters metal powder — heating particles to bond them without fully liquefying all material. SLM fully melts the powder into a homogeneous pool. In practice, modern DMLS systems achieve densities very close to SLM. SLM is preferred for mission-critical aerospace and medical applications where >99.5% density is required. DMLS is often more cost-effective for prototypes and medium production runs.
How strong are metal 3D printed parts?
Metal 3D printed parts achieve mechanical properties comparable to wrought material. SLM titanium typically reaches 144–153 ksi tensile strength. After HIP, fatigue performance meets aerospace standards. In some cases — particularly for stainless steels and titanium — printed parts exceed machined equivalents in elongation and hardness.
What materials can you print in metal 3D printing?
We print Ti-6Al-4V (titanium), AlSi10Mg (aluminum), 316L and 17-4 PH (stainless steel), Inconel 718 (nickel superalloy), and Co28Cr6Mo (cobalt chrome). Each material is selected based on application requirements for strength, temperature resistance, corrosion resistance, or biocompatibility.
How much does metal 3D printing cost?
Cost depends on material, technology, geometry, and post-processing. A typical small-to-medium part in stainless steel costs $150–$300. The same part in titanium costs $300–$600. Complex aerospace components in Inconel can reach $1,000–$2,000+. Upload your CAD file for an exact quote.
Can metal 3D printed parts be threaded or tapped?
Yes, but with important caveats. External threads larger than M6 can sometimes be printed directly but usually require chasing. Internal threads should be designed as holes 0.2–0.3 mm undersized and then tapped after printing. For precision threads, we recommend our hybrid workflow: print the blank, then machine threads on CNC equipment.
What surface finish can I expect from metal 3D printing?
As-printed SLM surfaces are Ra 5–10 μm. DMLS is typically Ra 10–20 μm. Bead blasting produces a uniform matte finish. CNC machining achieves functional smoothness. Polishing delivers near-mirror finishes down to Ra <0.4 μm.
Do metal 3D printed parts require post-processing?
Yes. All metal AM parts require support removal and stress relief heat treatment. Many parts also benefit from HIP, CNC finishing, or surface polishing depending on the application. Our metal 3D printing service includes standard post-processing; advanced treatments are quoted separately.
What file formats do you accept for metal 3D printing?
We accept STEP (.stp, .step), STL (.stl), IGES (.igs, .iges), and most native CAD formats. STEP is preferred for metal AM quotes because it preserves precise geometry. For best results, ensure your file includes critical tolerances and surface finish callouts.
Quote-ready manufacturing
Get Started with Metal 3D Printing
Whether you need one titanium prototype to validate a design or fifty Inconel brackets for a pilot production run, Baetro delivers metal 3D printing that combines advanced technology, material expertise, and manufacturing partnership.
Upload your CAD file for an instant quote with live pricing, lead times, and technology recommendations. Our engineers review every design — not just price it — so you get parts that meet your specifications the first time.
Parts ship in 5–10 days. No minimum order quantity. ISO 9001 & AS9100 certified.
Not ready to upload a file? Contact our engineers to discuss your project, review material options, or get guidance on metal 3D printing design.