Digital Metal now offers pure copper powder for 3D printing.
Copper’s conductive qualities have made it an ideal material for the traditional manufacturing of parts, especially those that require excellent electrical and heat transference. While pure copper hasn’t been available in the additive manufacturing (AM) sector, Digital Metal has changed that. It recently launched a 99.9 percent pure copper powder, DM Cu, that can be used with its DM P2500 3D printer.
“Whether for heat sinks, electrical motor and power grid components or resistance welding electrodes, 3D printed copper on the Studio System is an ideal choice for manufacturing parts featuring complex geometries,” said Jonah Myerberg, Desktop Metals CTO and co-founder.
As excellent as copper may be, it has proved to be a challenging material for 3D printing. Since it has high thermal conductivity, it is prone to delamination and layer curling. It also made removal of post-build powder difficult and usually required specialized handling and storage to avoid oxidation.
With copper being high on customers’ wish lists, Digital Metal set out to develop DM Cu. Through innovation and experimentation, the company conducted numerous tests with the new powder. The first part printed was a bullhorn antenna.
Often only needed in low volumes for specialized applications, this antenna directs radio waves in a beam. Using traditional manufacturing methods, costs associated with making them were high. Digital Metal was able to 3D print the part, which also allowed for the final product to be lightweight and made with ribs to ensure proper stiffness.
The next tests focused on printing Triply Periodic Minimal Surface (TPMS) heat sinks with a gyroid geometry. AM allowed a move away from pate and pin fin designs, which were hard to customize.
The 3D printed part provided increased heat transfer and rigidity over traditional parts. Since the baseline TPMS could be modified, the part boasts thicker walls and wider air passages at the base and thinner walls on top, optimizing heat distribution and convective flow. The ability to 3D print these parts inherently allows for customized parts.
The ability to use pure copper for 3D printing also lends itself to the medical industry. Along with its thermal conductivity and ductility, it has antibacterial properties. With the freedom to create unique geometric shapes, it may open up possibilities across sectors.
Along with creating DM Cu, Digital Metal has been busy the past two years developing new options to expand uses of AM in manufacturing. In 2019, it began offering two superalloy grades ideal for aerospace, automotive and industrial segments, DM 247 and DM 625. These metal materials are corrosion-resistant and able to handle high heat and stress. Last year, the company released DM D2, which is a tool steel alloy. This tough, abrasive-resistant option is ideal for many applications, especially for parts cutting and deformation tools. Since it is a high-carbon, high chromium alloy, it offers the option to be heat treated while also being suitable for cold work applications.
Interested in other metal AM news? Check out MakerBot Now Supports 3D Printing Metal with BASF Ultrafuse 316L.
