Which materials work best for additive manufacturing without tooling?

Polymers: The Foundation of Tooling-Free AM

For additive manufacturing (AM) processes that require no tooling, such as 3D Printing and Rapid Prototyping, a wide range of polymers excel. Photopolymer resins used in Stereolithography (SLA) offer high detail and smooth surface finishes, ideal for visual prototypes and master patterns for Urethane Casting. Thermoplastic filaments like ABS and PLA in Fused Deposition Modeling (FDM) provide good mechanical strength for functional testing. The most advanced option is Nylon (Polyamide), used in Selective Laser Sintering (SLS), which produces durable, complex, and heat-resistant parts without the need for support structures, making it a top choice for end-use components in low-volume manufacturing.

Metals: Direct Printing for High Performance

Metal additive manufacturing has advanced significantly, enabling the direct production of robust parts without traditional tooling. Technologies like Direct Metal Laser Sintering (DMLS) and Selective Laser Melting (SLM) are capable of processing fine metal powders. Aluminum alloys, such as AlSi10Mg, are widely used due to their excellent strength-to-weight ratio and thermal properties, which mimic many die-cast aluminum applications. Stainless steels (e.g., 316L) offer excellent corrosion resistance, while titanium alloys (e.g., Ti6Al4V) provide the highest strength and biocompatibility for aerospace and medical sectors. These processes are integral to our die castings Prototyping and complex component solutions.

Material Selection Criteria for Optimal Results

Choosing the best material depends entirely on the project's requirements. For conceptual models, cost-effective plastics like PLA or standard resins are sufficient. For functional prototypes that must withstand stress, heat, or chemical exposure, engineering-grade materials like Nylon, ABS-like resins, or metal alloys are necessary. When the goal is a small batch of production parts without the high cost of tool and die making, SLS Nylon or DMLS metals become the optimal choice. Our die castings Engineering team can advise on the most suitable AM material and process to meet your technical and budgetary needs.

Advanced Materials and Hybrid Workflows

Beyond standard polymers and metals, advanced AM materials are expanding applications. Flexible photopolymers and thermoplastic polyurethane (TPU) simulate rubber-like properties. Composite materials, such as carbon-fiber-filled Nylon, offer enhanced stiffness and strength. For applications requiring specific material properties that AM cannot provide directly, a hybrid approach is often best. A 3D-printed pattern can be used to create a quick, soft tool for Urethane Casting, which can then produce parts in a vast range of polyurethanes that mimic final production plastics, offering a bridge between pure AM and traditional manufacturing.