3D printing titanium and the bin of broken dreams | Hacker News Reader

3D printing titanium and the bin of broken dreams

pencerw.com

40 pointsprostoalex9 comments

The issues with part flex during the build process seem inherent to the "printing" technology. I wonder if the best way around this for metal might be to print a wax (or similar material) part, and then cast. Lost-wax casting would be difficult for the consumer, and if I'm to believe "How It's Made" is largely handwork even in industry. However, it might also be a process that could be improved by new, programmable tools.

Casting has similar entertaining issues with shrinkage and voids and embedded stresses. The thin parts and edges will cool much quicker than the edges.

You could anneal a block, and EDM the whole thing. Probably cheaper than the powder processes at this time and certainly the end result will either be lighter or stronger.

What does work w/ 3d printing and casting is printing your model in PLA or whatever, then sand casting around it, at least if its small. If its big you still win on time (and probably cost) using traditional woodworking to make the model.

Actually part flex during the build process is much more of a problem with milling and sometimes turning. There simply is a set of "forbidden" geometries where the tool would destroy the part, so nobody does them. The difference, as OP states in their article, is experience and craftsmanship.

In a similar vein, I've been thinking about trying to 3d print casting sand.

This company will 3d print a wax, then lost-wax cast that out of titanium. I don't know the price. They make PING golf clubs among other things.

http://www.dolphincasting.com/about.htm

A friend was quoted $14 per pound for steel, use that as a reference - about 25x the cost of raw steel.

The company I work for does Titanium DMLS. Can get a free automated quote too. http://www.protolabs.com/fineline

Titanium is also much harder to work with than steel. It really likes to oxidize when hot.

These guys have some Ti-capable technology currently flying under the radar, and are worth watching if you're in the market for an affordable, cost-effective solution to 3d printing metals:

http://shop.auroralabs3d.com/pages/about-us

The surface finish on the parts on their web site looks very, very rough - like coral.

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