Metal filament printing is shaking up the world of additive manufacturing. No longer just a tool for plastic prototypes, this technique is opening doors for hobbyists, designers, and engineers to work with metal like never before. Through extrusion-based systems using metal-infused filaments, users can produce functional metal parts right from their desktop printers.
As demand grows for on-demand, customisable, and lightweight components, this form of printing is finding a permanent home in industries across Australia, from research labs in Melbourne to engineering firms across Sydney.
The Basics of Extrusion-Based Metal Printing
Metal filament printing relies on a process that’s relatively similar to traditional FDM (Fused Deposition Modelling). Instead of standard thermoplastic filaments, these printers use filaments infused with fine metal particles, including stainless steel, bronze, copper, and occasionally titanium.
The printer extrudes the filament layer-by-layer to form a “green part.” This initial model contains a binder that holds the metal together. The part then undergoes de-binding to remove the plastic binder. This is followed by sintering in a high-temperature furnace to fuse the metal particles together. The result? A solid metal component with functional mechanical properties.
Affordability Meets Functionality
Unlike high-end methods or directed energy deposition, metal filament printing is cost-effective. It doesn’t need a clean room or inert gas chamber, making it accessible for small workshops, start-ups, and even home users looking to experiment with printing of metal parts.
Advantages
1. Lower Barriers to Entry
One of the biggest selling points is affordability. Most desktop 3D printers can be modified or upgraded to print with metal filament. This opens up metal part fabrication to a wider audience, helping foster a more inclusive maker community.
2. Ideal for Prototypes and Short Runs
Need a quick metal prototype? Metal filament printing delivers. It allows rapid testing and iteration without the need for expensive tooling or long lead times. Engineers in printing hubs are increasingly turning to this method to develop parts for the aerospace, automotive, and medical industries.
3. Easier Post-Processing
While sintering and de-binding are required, the post-processing workflow is far simpler compared to traditional powder-based systems. There’s no need for support removal via EDM or wire cutting, and surface finishing techniques like polishing and tumbling are easily applied.
Limitations to Consider
1. Mechanical Strength Isn’t Top-Tier
Compared to parts made using Selective Laser Melting (SLM) or Electron Beam Melting (EBM), filament-based components tend to have higher porosity and lower density. This affects strength and fatigue resistance. They’re suitable for prototypes, tooling, or decorative applications but not critical load-bearing components.
2. Shrinkage and Warping
During sintering, parts can shrink by up to 20%. This means accurate dimension control requires expertise. If you’re planning on trying your hand at this printing technique, you’ll need to account for shrinkage in your CAD models to avoid costly redesigns.
3. Support Structures Are Often Needed
Unlike binder jetting or powder bed fusion, metal filament printing typically requires support structures to prevent warping during the print and sintering stages. This slightly limits the freedom of design, although modern slicing software mitigates these constraints.
Comparing Metal Filament with Other Printing Methods
Powder Bed Fusion (PBF)
PBF, including SLM and EBM, is the gold standard for precision metal parts. These processes offer high resolution and exceptional strength but come at a premium cost. They also require significant safety measures and specialised training.
Binder Jetting
This method is both fast and cost-efficient for small batches. However, it suffers from high porosity and relies on post-processing similar to filament methods.
Directed Energy Deposition (DED)
DED is ideal for large-scale repair and production applications but demands high initial investment. It’s primarily used in aerospace and defence due to its ability to add material to existing parts.
In contrast, metal filament printing provides a middle ground—less precision than SLM but far more accessible for small-scale users in industries scattered throughout Australia.
Emerging Applications
Jewellery and Fashion Accessories
Designers are using it to create custom rings, pendants, and fashion pieces. With materials like bronze and copper available, jewellers can offer unique, one-off designs without the expense of lost wax casting.
Dental and Medical Prototypes
Metal 3D printing applications are gaining traction in dentistry for temporary crowns and implants. While not a replacement for fully certified implants, filament printing enables fast iterations and anatomical models for surgical planning.
Tooling and Jigs
Workholding tools, fixtures, and alignment jigs can be quickly made using this method. These tools improve efficiency and reduce downtime in manufacturing environments.
Automotive Customisation
Small automotive shops in cities like Sydney and Melbourne are taking advantage of this technology to produce brackets, shift knobs, and other custom metal parts without needing extensive machine shop resources.
Growth of Metal Printing in Australia
In Australia, local universities, research institutions, and start-ups are investing heavily in metal printing technologies. With an increasing number of local businesses offering 3D printing services in Sydney and Melbourne, like CAD Deziners, access to metal printing is growing fast.
Government initiatives and educational programs are helping bridge the skills gap. As more engineers and designers become familiar with metal filament printing, adoption rates are expected to climb, especially among SMEs seeking flexible production capabilities.
What the Future Holds
Metal filament printing is still evolving. As manufacturers refine filament formulations and sintering techniques, the quality gap between extrusion-based and powder-based parts is narrowing.
Expect to see:
- Better shrinkage compensation tools in slicing software
- Wider material availability (e.g., tool steels, titanium)
- Integrated de-binding and sintering systems
- More user-friendly workflows tailored to small businesses
As these improvements roll out, metal filament printing will become an even more attractive option for professionals in prototyping, small-scale production, and personalised manufacturing. The future looks promising.
Conclusion
It is more than just a novelty; it’s a practical, cost-effective way to fabricate metal parts. While it doesn’t yet match the mechanical properties of high-end metal printing techniques, it’s closing the gap and expanding access across industries.
From prototyping in local labs to tooling in small machine shops, metal filament printing reshapes how Australians approach manufacturing. As it becomes more advanced and user-friendly, this method will continue to unlock creative potential and manufacturing freedom across the country.
If you are on the hunt for reliable 3D Printing in Melbourne or Sydney, we should be your automatic go-to. Not only do we offer the best metal printing services, we also have decades of expertise in providing all types of additive manufacturing, including CNC machining and SLS printing. Give us a call today!