Metal 3D printing, also known as additive manufacturing with metals, is revolutionizing manufacturing across industries like aerospace, medical, and automotive. The ability to 3D print complex metal parts with intricate geometries and custom alloys is enabling companies to optimize designs, consolidate assemblies, and reduce waste.
However, metal 3D printers have traditionally carried a high price tag that has put them out of reach for many small businesses and makers. But as the technology matures and more competitors enter the market, prices are starting to come down. In this article, we’ll look at the current range of costs for metal 3D printing systems and the factors that influence pricing.
Key Factors That Determine Metal 3D Printer Costs
There are several key specifications of a metal 3D printer that impact its price:
- Build Volume – The maximum part size a printer can produce. Larger build volumes allow printing bigger parts and higher production volumes.
- Print Resolution – Printers with finer resolution produce higher detail and surface finishes but are slower. Typical resolution ranges from 20 microns to 150 microns.
- Print Materials – Printers that support more metals and alloys have a wider capabilities but higher costs. Most common metals are stainless steel, aluminum, titanium, nickel alloys, and cobalt-chrome.
- Print Speed – Faster print speeds increase production throughput. However, quality often declines at very high speeds.
- Software – User-friendly software and automated features improve usability and productivity.
- Manufacturer’s Reputation – Industry leaders charge a premium for their proven reliability and customer service.
Entry-Level Metal 3D Printers ($100,000 – $250,000)
At the low end, metal 3D printers typically utilize Directed Energy Deposition (DED) technology. A focused heat source like a laser or electron beam melts metal powder or wire as it is deposited to build up parts layer by layer.
Key features of entry-level systems:
- Modest build volumes under 1 cubic foot.
- Print resolution around 100 microns.
- Basic metals like stainless steel and aluminum.
- Slow print speeds under 100 cm3/hour.
- Manual software with limited capabilities.
- Basic training and support.
Example entry-level DED printer:
- DM Studio System by Desktop Metal – $120,000. Up to 212 cubic inches build volume and 75 micron resolution.
Another emerging low-cost option is bound metal deposition. It uses metal composite filament extruded through a heated nozzle to 3D print parts. The printed parts are then sintered to fuse the metal powder into a solid part.
Example bound metal deposition printer:
- X1 160Pro from Tractus3D – $36,000. Steel and bronze composite filaments. 5.1 x 5.1 x 6.3′′ build volume.
Mid-Range Metal 3D Printers ($250,000 – $1,000,000)
Moving up in price, mid-range metal printers offer faster speeds, larger build volumes, and more advanced features. Most use powder bed fusion technology, where a laser or electron beam selectively melts powder layered in a bed.
Key attributes of mid-range metal 3D printers:
- Build volumes up to 10 cubic feet.
- Print resolution down to 30 microns.
- Broad range of metals including steels, titanium, aluminum, nickel alloys, and more.
- Moderate print speeds of 50-150 cm3/hour.
- Automated software features like auto-orientation and nesting of parts.
- Expanded training and professional services.
Example mid-range system:
- Studio System 2 from Desktop Metal – $495,000. 16 liters build volume and 50 micron resolution. Over a dozen materials like stainless steels, tool steel, copper, and more.
High-End Metal 3D Printers ($1,000,000+)
At the top end of the market, these high-performance systems offer very large build volumes for mass production, multi-laser or electron beam configurations for ultra-fast print speeds, and capabilities to print complex reactive metals and super alloys.
Features of high-end metal 3D printing:
- Massive build volumes over 10 cubic feet.
- Exceptional print resolution down to 10 microns.
- Exotic metals like titanium, Inconel, Hastelloy, and more.
- Blazing print speeds over 500 cm3/hour with multiple beams.
- AI-powered software for automation and optimization.
- Comprehensive training, service contracts, and global support.
Example high-end system:
- X Line 2000R from GE Additive – $1.3 million. Nearly 2 cubic meter build volume. Tri-laser configuration for high productivity. Over 10 materials like titanium, nickel alloys, tool steel, and more.
Other Considerations Impacting Total Costs
Beyond just the 3D printer itself, there are additional expenses to factor into a budget for metal additive manufacturing:
- Materials – Metal powders and wire can range from $50-$500 per kilogram. Parts often require supports using more material too.
- Post-Processing – Most printed parts need secondary machining, polishing, heat treating or other finishing to meet final specifications.
- Facility Requirements – Metal 3D printers need industrial electrical supply, ventilation, compressed air and other infrastructure.
- Software – Additional software for design, simulation and workflow management.
- Labor – Operators need extensive training to achieve quality prints and maximize productivity.
- Maintenance – Regular calibrations, services and spare parts are required to sustain performance. Warranty and service contracts are recommended.
- Safety – Protective equipment for handling reactive metal powders must meet regulatory compliance.
The Total Cost of Ownership (TCO) for a metal 3D printing system includes these recurring costs in addition to the printer purchase price. Carefully evaluating the full long-term costs and ROI versus alternative production methods is advised.
Current Trends in Metal 3D Printing Pricing
The high costs associated with metal 3D printing have restricted adoption mostly to deep-pocketed industrial leaders in aerospace, medical device and automotive sectors. But expanded demand is allowing economies of scale and driving increased competition which is bringing down pricing.
Other trends making metal 3D printing more attainable include:
- Declining prices of key components like lasers and optics.
- Introduction of lower-cost binder jetting and bound metal deposition technologies.
- Expansion into smaller benchtop machines tailored for universities, startups and SMBs.
- Growth of metal 3D printing service bureaus enabling businesses to outsource production rather than purchasing printers.
- Development of leasing and financing options that spread out upfront costs over time.
Major players like GE, 3D Systems and EOS are now offering metal 3D printers under $100,000 to reach wider markets. And increased competition from newcomers like Desktop Metal, Markforged and Xact Metal is further expanding the range of affordable options. We can expect expanded adoption of metal additive manufacturing as prices continue trending downward over time.
The Bottom Line on Metal 3D Printing Costs
Metal 3D printer prices currently range from around $100,000 on the low end up to $1 million+ for high-end industrial systems. The specific price varies widely depending on build volume, materials, print speed, and other capabilities.
But the broader trends of expanded adoption and increased competition are bringing down costs and making metal 3D printing technology more accessible. Forward-looking companies would benefit from starting to evaluate how metal additive manufacturing could improve their product designs and manufacturing processes before prices fall further. Partnering with a professional service bureau provides a low risk way of getting started with metal 3D printing.
