BASF Ultrafuse 316L stainless steel filament
The ability to 3D print with metals on the desktop has long been the dream for many a maker. When Desktop Metal teased its name back in 2015, the anticipation was high for a lower-cost desktop solution, and even before that, companies like The Virtual Foundry have been providing users with high density filaments to affordably print in metal and ceramic.
Earlier this year, the additive manufacturing (AM) arm of global chemical company BASF decided to throw its hat into the ring and formally launched a metal-polymer 3D printing filament onto the market. First introduced around two years ago, Ultrafuse 316L has been through an extensive testing process with select customers and partners, and is said to enable simple and cost-efficient production for metal parts on any extrusion-based 3D printer.
TCT spoke to François Minec, Managing Director and CCO at BASF 3D Printing Solutions to find out where this material fits into the market and how it is expanding capabilities for desktop users.
TCT: There are a number of metal solutions on the market aimed at FFF machines – can you specify what makes this particular material unique?
FM: There are two main aspects that differentiate this filament from others in the market.
Ultrafuse 316L has been developed based on BASF’s deep know-how in Metal Injection Molding (MIM) technology, specifically in developing and commercialising catalytically debindable feedstocks. Catamold offers the highest debinding rates and therefore highest production rates; the process is carbon-free, meaning no carbon is left over in the steel that might compromise mechanical properties. Ultrafuse 316L green parts are very strong and can be shipped easily, while the debinding process is a gentle, fast gas-phase process that minimally stresses the occurring brown parts.
The special, patent pending morphology of the filament offers high strength – that is, the filament does not rupture during processing – outstanding flexibility that allows low bending radii and spooling without breaking, and excellent printability.
Ultrafuse 316L metal 3D printed robotic gripper
TCT: Are there any specific application areas where you see the material having the biggest impact?
FM: Definitely. The whole metal FFF field is currently in the application-development phase. We anticipate that initial applications will occur in the field of tools, jigs and fixtures, with components joining at a later stage.
TCT: The material takes a similar three-step process to binder-jet technologies – does this have the potential to shake-up that market as a low-cost alternative to current metal printing?
FM: We are convinced it will. It makes investment in an expensive system unnecessary, and customers can access our network for debinding and sintering. This makes the entry effort into metal 3D printing very low and inexpensive. Even better, many customers already own an FFF printer and can therefore start printing metal components directly.
The low part-cost of ownership makes this technology outstandingly competitive. FFF/FDM technologies are well positioned thanks to the low cost of the printing platform in comparison to binder jetting.
TCT: The material is said to be suitable for any FFF 3D printer – are there any particular conditions or extra design guidelines that need to be taken into consideration?
FM: Based on our own experience and from what we have seen on the customer side, Ultrafuse 316L does indeed print very well on an impressive variety of printers. Here, enclosed build chambers and a heated bed are definitely a plus.
In our User Guide, we recommend using a standard FFF printer with an enclosed chamber. Of course, with our technology too there are some basic rules to follow in order to create a successful part. Remember that “a great part starts with great design” – and this is also explained in our User Guide. To get the best out of our technology, our constant message to customers is "think additive".
The material is said to enable simple and cost-efficient production for metal parts on any extrusion-based 3D printer
TCT: Do you think materials like this will further increase the acceptance and adoption of desktop FFF 3D printing as an industrial tool?
FM: No doubt whatsoever. FFF printers have been regarded as the hobbyist´s choice in the past, with the industrial sector leaning more towards the other 3D printing technologies. We can now see that FFF printers’ significant improvements in accuracy and reproducibility make them very suitable for industrial uses. For metal applications, whenever low part-cost is crucial and surface quality is less important, metal FFF could be an attractive alternative.
The process is becoming more and more professional and reliable, so that industrial standards can already be achieved with this technology. FFF printing is cost-effective and easy to use, so everyone can access this technology quickly and easily.
The user perspective from Dave Gaylord, Head of Product at MatterHackers ...
"MatterHackers' customers are always looking to expand the capabilities of their desktop 3D printers and Ultrafuse 316L is the biggest leap we have seen in some time. The ability to produce true, pure, industrial-grade metal parts easily and affordably is a huge technological advancement for the desktop space and shifts the mindset of thinking about what is possible with a desktop 3D printer.
Affordable desktop 3D printers are constantly finding applications in new places from the home, office, workshop, to a studio or manufacturing floor. The addition of metal 3D printing allows the next level of adoption - I see Metal Injection Moulding facilities and classical Machine shops really embracing the fast iteration cycles and production capabilities of BASF's new material in conjunction with reliable hardware that is available today."
TCT: Finally, can we expect to see more metal filaments in BASF’s product roadmap?
FM: We are planning to include more metal types in our portfolio. Ultrafuse 316L is a great material with an extensive application spectrum and a good place to start.
BASF will exhibit at Formnext in Frankfurt on 19-22 November in hall 12.1, stand D21. Register for your showfloor ticket here and visit the TCT @ Formnext Conference website to register for your conference pass.
