Guide to Metal 3D Printing Cost [+Free Cost Calculator]

Here are two 3D models of the same part but in different shapes: a solid cube (a), and a lattice structure (b). Which one do you think is easier to print and costs less using metal? It's easy to mistake that the simple solid cube is easier to print and costs less, while the complex lattice is harder to print and costs more.

But it is exactly the opposite way: generally speaking, the lattice structure is easier to 3d print and costs less than the cube using the same material. Here’s why:

• Less material: the lattice has many gaps, using less material while maintaining strength, whereas the cube requires more material to fill.

• Faster printing: the lattice has smaller print areas per layer, reducing print time; the cube needs to fill each layer, taking longer.

• Better cooling: the lattice distributes material evenly, reducing overheating or warping and lowering failure rates.

• No supports needed: the lattice is cleverly designed with built-in support, while the cube may require extra support, increasing costs and post-processing time.

However, lattice is just one of the many factors that affect 3D printing costs. There are many other factors not mentioned. Today, let’s uncover the mysteries of metal 3D printing cost together.

Metal 3D Printing Technologies and Materials

Before we break down the cost of metal 3d printing, it is rather necessary to clarify how metal 3d printing works. That is, clarify the technologies and materials applicable for it.

Technologies

SLM and Binder Jetting are the two commonly-used 3d printing technologies.

Selective Laser Melting (SLM)

SLM is a 3D printing process that uses a powerful laser to melt metal powder and fuse it together to form a solid object. The process begins by spreading a thin layer of metal powder on the build platform. The laser then scans the powder, melting it to create the desired shape. After each layer is melted and solidified, the platform lowers, and a new layer of powder is added. This process repeats until the entire object is built.

Binder Jetting (BJ)

Binder Jetting is another 3D printing process that works by depositing a liquid binder (a glue-like material) onto a bed of metal powder to bond the powder particles together. The binder is applied layer by layer, and once the entire object is built, the part is removed from the powder bed. The part then undergoes a sintering process, where heat is applied to further solidify the material.

SLM vs. BJ

In Summary

• Go for SLM if you need high strength, precision, and durability in parts where post-processing should be minimal.

• Choose Binder Jetting if speed and cost-effectiveness are more important than absolute strength, or if you're working with larger volumes and don’t mind the additional sintering process.

Materials

The table below has compared the common metals used in 3d printing in terms of 6 aspects to help you choose the most suitable material for your printing.

How to Calculate Metal 3D Printing Cost?

The cost of metal 3D printing typically includes several components: material cost, post-processing cost, logistics cost, and taxes. Here’s how each of these factors is calculated:

Material Cost

Material cost is usually calculated according to the formula below. Usually, when the material price per gram is determined, the service provider has already factored in both the material cost and the printing cost.

Material Cost = Model Volume × Material Density × Unit Price per Gram of Material

The following is an example to help you better understand the formula.

(*The material price listed here is for illustrative purposes only and should not be taken as a reference. However, in most cases, the more you print, the lower the total cost.）

Post-Processing Cost

Post-processing costs can vary significantly depending on several factors, such as the type of post-processing required, the size and complexity of the part, the material used, and the printing technology applied. There are three common pricing methods for post-processing:

• Hourly Rate: Many post-processing service providers charge based on the time required for processing, especially for complex surface treatments or mechanical machining.

• Per Part Rate: Some simpler post-processing tasks are charged on a per-part basis.

• Weight or Volume Rate: For post-processing steps that require heat treatment or other resource-intensive processes, some providers charge based on the weight or volume of the part.

Logistics and Taxes

In addition to material and post-processing costs, metal 3D printing costs also include logistics and taxes. Weight-based logistics cost varies across different regions and companies. Taxes will depend on the region and applicable laws, and they are often calculated as a percentage of the total cost. For more detailed information about the two, you can refer to the article: https://www.unionfab.com/blog/2024/10/how-much-does-it-cost-to-3d-print-something

How to Reduce 3D Printing Costs?

Reducing 3D printing costs is a strategic process that involves optimizing design, selecting the right materials, and improving production efficiency. Here are some practical tips to help you save money on your 3D printing projects:

Optimize Your Design

• Simplify the Geometry: Complex designs take more time and material to print. Simplifying unnecessary details can significantly lower costs.

• Use Hollow Structures: Replace solid parts with lattice or hollow structures to save material without compromising strength.

• Consolidate Parts: Combine multiple components into a single design to reduce assembly time and production cost.

Reduce Model Volume

• Scale Down When Possible: Smaller models require less material and shorter print times. If the part doesn't need to be full-sized, consider scaling it down.

• Thin Walls and Reduced Infill: Use thinner walls and low-density infill to save on material usage.

Choose the Right Material

• Cost-Effective Materials: Opt for materials that meet your requirements without overspending. For example, use aluminum instead of titanium for lightweight applications with moderate strength requirements.

• Minimize Material Waste: Design with material efficiency in mind, especially for expensive metals like Inconel or titanium.

Choose the Right Printing Technology

Different 3D printing methods have varying cost structures. For instance:

• Binder Jetting: Better for high-volume production with lower material costs but requires additional sintering.

• SLM/DMLS: More expensive but ideal for high-strength, intricate parts.

Optimize Post-Processing

• Simplify Post-Processing Requirements: Choose finishes that meet, but don’t exceed, the functional needs of your part.

• Batch Processing: Group similar parts together to minimize setup costs for post-processing tasks.

Get Started with Unionfab’s Free Cost Calculator Today

Free Cost Calculator

If you're curious about the cost of 3d printing your model with a specific metal, feel free to try our free online cost calculator!

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Cases Display

Here we have displayed the metal prints that we have finished across different industries.

Industry	Case
Automotive
Aerospace
Industrial
Medical
Design