Aluminum 3d Printing is revolutionizing manufacturing, and Aluminum 6061 Filamet™ stands at the forefront, making metal 3D printing more accessible than ever. This innovative filament, available in both 1.75mm and 2.85mm diameters as well as pellets, allows you to create genuine aluminum parts using standard Fused Filament Fabrication (FFF) 3D printers.
What is Aluminum 6061 Filamet™?
Filamet™ is a specially formulated composite material designed for metal 3D printing. Aluminum 6061 Filamet™ comprises 60% – 69% metal powder within a thermoplastic binder. It is available in convenient 0.25kg and 0.5kg spools, and also in 1kg bags of pellets, catering to various project sizes and production needs. With a density ranging from 1.2g/cc to 1.5g/cc before sintering, it offers a tangible feel of metal even in its filament form.
Key Advantages of Aluminum 3D Printing with Filamet™
Universal Compatibility
One of the most significant benefits of Aluminum 6061 Filamet™ is its compatibility. It is engineered to work with virtually any open-architecture FFF 3D printer. This eliminates the need for expensive, specialized equipment, opening up aluminum 3D printing to a wider audience, from industrial users to hobbyists. Remarkably, it can even be used with 3D printing pens, showcasing its versatility.
Simplified Printing Process
Printing with Aluminum 6061 Filamet™ is designed to be as straightforward as using standard PLA. To get started with aluminum 3D printing, you will need:
- An open architecture 3D printer
- A 0.6mm hardened steel nozzle (essential for abrasive metal filaments)
- Your desired 3D model
The printing process itself closely mirrors PLA printing. It is recommended to ensure the filament path is straight into the extruder for optimal feeding. You might need to slightly increase the flow rate in your slicer settings, potentially up to 135%, to achieve the best results. A key advantage during printing is minimal warping, contributing to dimensional accuracy and successful prints.
Advanced Material Properties Post-Sintering
Aluminum 6061 Filamet™ offers more than just ease of printing. It boasts advanced material properties once it undergoes sintering. Unlike standard PLA, Filamet™ is less hygroscopic, meaning it absorbs less moisture from the air. Notably, filament dryers are not recommended and should be avoided as they can negatively impact the filament’s properties. It is best practice to store spools as delivered to maintain their optimal condition.
The transformative step in achieving true aluminum parts is sintering. After being fired in a sintering furnace, the binder material is removed, leaving behind a part that is 100% solid metal. The sintering process is under continuous development, with ongoing updates and information available on platforms like YouTube and the Virtual Foundry Discord server (here).
Exceptional Material Qualities
The resulting sintered aluminum parts exhibit the desirable qualities of 6061 aluminum:
- Strength: Capable of withstanding significant loads and stress.
- Lightweight: Aluminum is inherently less dense than steel and other metals, making it ideal for weight-sensitive applications.
- Corrosion Resistance: Aluminum 6061 is known for its excellent resistance to corrosion in various environments.
Broad Applications for Aluminum 3D Printed Parts
Aluminum 3D printing with Filamet™ opens up a wide range of applications. Partner innovators are already leveraging this technology for:
- Light-weighting: Reducing the weight of components without sacrificing strength, crucial in aerospace, automotive, and robotics.
- Research and Development: Rapidly prototyping and testing new metal part designs.
- Short-run Manufacturing: Economically producing small batches of custom aluminum parts, eliminating the high costs associated with traditional tooling and machining.
- Prototyping: Creating functional prototypes in the final material, aluminum, for accurate testing and validation.
- One-off Metal Parts: Manufacturing unique or replacement metal components on demand.
Aluminum 3D printing with Aluminum 6061 Filamet™ is changing how we approach metal part creation. It provides a cost-effective, accessible, and versatile pathway to producing high-quality aluminum components directly from your desktop.
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