How Strong is 3D Printed Metal?
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- เผยแพร่เมื่อ 20 พ.ค. 2024
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Updated strength test video here: • 3D Printed Metal vs CN...
A little while back I designed a snap close connector (STL link below) and some of you wanted to know just how strong it was. But I also wanted to find out how strong the design could be if it was 3D printed in metal. PCBWay were kind enough to provide me with aluminium (AlSi10Mg) and stainless steel (316L) 3D printing services. Using their selective laser melting (SLM) 3D printers they printed some amazing parts that I assembled into my snap clips (frog). Next, I needed to build a tensile strength testing rig to test these things - and it was going to have to be strong! So I built a 1 tonne tensile testing machine that uses a bottle jack to tension the parts. The results were a little surprising!
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Electrosync designs featured in this video are available for free at Thangs.com:
Snap Close Connector:
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Print Buster 3000 - 1 Tonne Tensile Test Rig:
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CAD design was done in Fusion 360. Shot on Canon EOS M50, Insta360 One R, Insta360 Go 2, DJI Mini and iPhone for slow motion. More information electrosync.com.au/2022/05/03...
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Time Stamps
0:00 Intro
0:22 SLM 3D Printed Parts
1:28 Building a Strength Tester
3:12 Strength Testing the Parts
7:57 Wrap Up
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#3Dprinted #Metal #Strength - วิทยาศาสตร์และเทคโนโลยี
It would've been great to see how a 3D-printed metal compares to the same metal, but machined.
Stay tuned...
@@electrosync I'm interested. 🤔
I think stamped aluminium and steel would be great too!
Mechanical properties of aluminum and steel are known...I would find intersting too to compare machined and printed samples...and it would be much better if you use standard sample usually adopted in these cases (it is usually a small bar with the terminal part thicker in order to induce the sample to fail in the middle part), with a known cross sectional area. Another thing that I have noticed in your video, in fact, is that no one of the 2 hooks made by pointer metals began to yield before fail. This is an important diffrrence with respect to machined metals, where the piece, before failure has a permanent deformation. This behaviour is and advantage of metals over, for example, composites because it advice you before failing. Composites instead are fragile and fail suddenly. If printed metals should lose this their feature with respect to machined ones, it would be, for me, a big concern.
He's going to need an upgrade for test rig already 🤣
The slight difference between the stainless steel and aluminium might be because of the melting points. During 3D printing, aluminium might melt more efficiently and bond together more strongly because of its lower melting point.
Also the stainless steel looked like it might have had some voids.
But to be fair stainless steel is not particularly known for great tensile strength either.
@@nocturnal0072 316L Ultimate Tensile Strength is 515 MPa while that of AlSi10Mg is at max 450 MPa. That is about 14.5%. The AlSi10Mg though has a higher Yield Strength than 316L. If this were a straight up test of a fixed object it shouldn't matter but we are looking at a complex assembly and the 316L assembly going plastic first could very well have seen loading on individual areas of the assembly increase on the 316L as others went plastic.
Also, as said, the 316L "looks" like it may not be perfectly sintered but we are looking at something already torn apart.
Bottom line, without testing a simple test part lacking moving features and assembly it is very hard to make a direct comparison.
@@kennethfharkin 4340 steel quenched in oil at 315 C has a tensile strength of 1,760 MPA.
The alloy contains nickel, chromium and molybdenum Just like 316 SS does but not as much concentration of those elements.
@@darkshadowsx5949 yes but what does that have to do with the 316L which was DLS printed?
it makes sense.
The cost difference for aluminum and SS makes the slightly lower strength of the aluminum compelling for the 3D printed versions. I think the SS would be lots stronger except that the melting point is much higher and that was probably making for poorer bonding of the metal powder. If these clips were made from actual solid aluminum or SS I think the strength would be much better. You can see the porosity of the metals...that's going to make 3D printing weaker.
If the SS was caste as opposed to printed it would have doubled aluminums performance.
He could make compatrison betwean printed and caster parts. More useful.
That is a valid point you made there, I would like to see the test results of the same apparatus made from the traditional methods of casting vs 3D printing.
Genuinely surprised with how much PLA could hold!
probably hold more if he printed it solid and beefed up the weak area.
could hold me twice !
@@thecaptainnoodles schmol
It can hold like 10 of me
What is that glass object @00:39 😳
hæææææææææ
I was searching 5 min for this comment bc i knew i wasn't the only one who noticed that
Thanks for the effort done for the strength test.
Thanks for watching!
Well, that was fun! What else can I test on this contraption? Edit: I've made a newer video testing different material processes here: th-cam.com/video/Js3bJ1B8ySM/w-d-xo.html
The only test that matters is to compare the strength of traditionally manufactured parts vs 3D-printed parts.
A bogan mullet
I agree with Ivo, I'd like to see a machined part comparison in aluminum and steel.
Same design &materials, traditionally forged methods.
who is stronger under the same weight,cn or 3d print？
That's amazing! It is something new for me about metal 3D printing.
The fact no one in the comments noticed a but plug at 0:38 is truly amazing
I got a Frog for my birthday back in 1999 and drove my dad nuts fidgeting with it. I printed one out last year and it has been one of my favorite prints since. Thanks a ton.
Glad to hear!
Great designed part. Great video and incredibly informative. Additive machining has come so far.
How do you not have more subscribers? Your videos are awesome!
I love how this guy puts so much time making these video’s
that was pretty cool sir
those clips you made are pretty slick too ...
Excellent video!
It would be interesting to see the difference between 3d printed, machined and stamped aluminium and steel too.
I’d be interested to see how the same components made from sheet Aluminium and stainless steel performed and if their failure points were the same.
Great idea! I'm working on a follow up to this video and I'm looking to include some laser cut parts, plus some more exotic materials...
@@electrosync
I'm looking forward to seeing how the gold, platinum and adamantium ones perform.
@@electrosyncwell the metal is stronger then my will to survive so pretty solid😎👍💯
It would be interesting to see weight matched comparisons. Even if it's just for the PLA, a 50g and 100g version would be cool to see in comparison to metal parts.
Love this design! Considering scaling it up and adapting it for a completely unrelated application! Thank you!
Sounds fun! I made one at 200% scale and it worked well with heavier gauge wire for the torsion spring.
You need to look into Hot isostatic pressing if your interested in possibly making them even stronger
The aluminum and stainless were VERY impressive, atleast to me. 🤯🤘👍
Great vid, were these raw metal or were they heat treated? because the stainless steel may of been soft due to looking at the grain of the breaks it is rather coarse 07:39, im not a metal worker or smithie but after watching Forged in fire they always talk about the grain
I absolutely love this content thank you! 👍
I kept wondering why the pivot bolts didn't shear off. I would have thought on the metal parts those would have gone before the printed parts.
I'm also wondering if heat treating would work on metal parts. That might be another interesting experiment for the future.
Tysm, did everything as described
I'm impressed that the aluminum part was able to bend a steel tube like a bendy straw.
Tq for your video.it make me more confident to print stainless steel and aluminium with pcbway.
I’m glad it was helpful. Thanks for stopping by!
really thanks 👍 very informative
You should off printed PLA+ with solid infill, it could haa make some difference, 100Kg is still quite impressive for a printed plastic
You noticed the sponsored metal parts were solid while the non sponsored plastic where lightly infilled. Not to say PLA ever had a chance but lets see apples vs apples. Solid CF filled nylon would have been a lot fairer comparison.
it would be even nicer if the test was made with same parts and materials with 3D printed vs CNC made, so like that we know how strong 3d print vs parts made from forged metal.
Planning this...
looks like the laser bonding required encouragement to work on the stainless steel, like a magnesium powder or some such catalyst, it should be a lot closer to solid internally, its so strange to see such thorough internal blackening, but then I've never seen a broken stainless 3d print either!
Larger stainless bolts, and fileting the edges will greatly increase the strength of the unit. With 3D prints there are a lot of stress risers on those sharp corners. Nice video!
you got that right, didnt notice that, they are basically covered in stress raisers, too bad he didnt get matched parts with water-jet cutting etc. and test them against the printed stuff. 3d printing is a bit of a religion and some people are afraid of knowing the truth about the material limits.
Its amazing how each metal had vastly different sheer characteristics, in the sense where that fractured.
Nice ! Thank you!
Was the steel heat treated in any way after printing? I've gotta wonder if tempering might have helped.
My thoughts exactly, especially for the stainless.
from my experience, this looks like bad quality steel with no heat control, normalization or heat treat, the grain structure of the steel is closer to grey cast iron, its not good quality at all
@@azpatriot7937 That’s the quality for 3D printed metals for a part I had printed. It all depends on application. My print was for a part in my door latch that broke. Similar latch $240 and would have to sand and repaint door. Company no longer made that model and so designed and printed by Shapeway in SS. About $8 seven years ago and still going strong. Worth checking out all the items and materials available on Shapeways.
I had a good laugh at the part buster bending. I was just noticing the weight slowed way down when you revealed why.
You would think I would have caught it earlier, but when I'm filming I'm looking all over the place!
tapping with the part loose in your hand you madman! of course the tap broke
I would like to see them in a fast stress test. Could this eventually be used in tree or rock climbing gear? How many Kn
I would love to see the same test with forged metal vs. printed to see the difference. Good stuff
Forged would be significantly stronger, but the nice thing about 3d printing is that you can make complex parts without specialized equipment or much skill (relatively).
Hey, blacksmith here! You know this new way of making metal parts reminds me of the old ways, in the sense that before mass melting furnaces were a thing, people would process iron trough forge welding sometimes very small pieces together (a bit like the Japanese and the tamagahane). So welding something together will get you to good results, but modern homogenous steels are still superior tho.
I think a good forge welding heat forging would help his 3d printed parts actually stick together more into a solid piece.
Also the grains look disgusting... His metal parts definitely need tempering cycles
@@jeanladoire4141 Forge welding isn't easy for high carbon steels, and it's really impractical for most uses. Metal 3D printed parts are sintered for a couple hours, though the finish of these specific parts seems a bit off.
@@ignacioaguirrenoguez6218 i'm familiar with forge welding high carbon steel, it's not that it's "not easy", it just wants to crack and burn at high temperatures, but there are ways of solving these problems. Now i dont see why you'd make structural pieces out of high carbon steel, most commonly used stuff for high strength structural parts is like S325, something with like 0.35% carbon
Love the OSHA approved footwear @ 1:50
Wow you don't have to retire your Print buster 3000, it can be a star in future test episodes!
I just uploaded a vid where it’s the star!
I would love to see a machined part out of billett or such to truly test how strong 3d printed metal is versus machined metal
I'd love to do it, but do you think it would break under 1 tonne? I might have to build a stronger rig!
@@electrosync it would be close. Aluminum yes, but steel I doubt it would break. You would be pushing it, I think 5 to 10 ton rig will be needed for that
@@CL-yp1bs surely it would depend on what the part is and its design? there are aluminium screwgate carabiners that are used in climbing/work at height that are rated for 25 kN on the major axis.
The printed metals seemed badly porus.
@@spudpud-T67 they're typically 99.9X% dense as-printed with the right laser parameters. But after hot isostatic pressing, which is typically performed, you have virtually no porosity.
could try to super size a bunch of bency's in differnt material like PLA, TPU and ABS and stretch it from bow to stern til it snaps. Would look epic in slow motion
I like the sound of that. I'd love to see a giant TPU benchy stretched out on there!
What was the song you used?
I would have expected Stainless to be much stronger than Aluminum.
Thought it was going to by boring old SLS, but proper SLM ! NOW WE’RE TALKING!
Wondering if mixing the aluminum and steel parts that didn't fail would be stronger
To me the aluminium was superior as the jaws didn’t fail in any way. The stainless jaws began to fail at 884kg. The aluminium clip failed only a little lower than this, but not the jaws, which looked good. The way the aluminium clip did break, at the bottom, I believe a couple more stainless screws low down would add significant strength and potentially outperform the stainless steel clip. Of course just a little more force could make all the difference, but unless tested we won’t know.
Really want to see how CNC parts perform against 3D printed ones.
From what I've gathered after a mediocre amount of research, the 3D printed parts have micro-faults that don't necessarily cause problems unless put under extreme pressures. It's due to how the fusing of the metallic structure is applied. So CNC'd parts are most likely going to out perform by a noticeable margin most likely.
It would be cool to see the comparison indeed.
Follow up video is in the making with CNC and laser cut parts.
Was that PLA on 20% in-fill. Kinda like PLA-light
So would aluminum based filament on a fdm printer be as strong as that aluminum clip u received from pcb?
this is basically the george, gina & lucy handbag clip. there is a video of different metals, including titanium, with the same tests comparing 3d print and cnc.
it seems like it was the hardware that gave way first on the aluminium unit not the eye, maybe a bigger centre bolt and a couple of smaller clamping bolts just above the eye could help increase the load these can take.
nickel titanium alloy would be dope, I'm looking to get into weaving nitinol soon, it looks promising for all 3d printed metal fields.
A few issues I noticed. The stainless steel wasn't tempered properly. The clip you designed is ok but consider the bottom hole it is made of two parts that are pulled on unevenly by the test rig.
That isn't a problem with the test rig but the clip design. The hole edges need to be rounded over also it would help if there was a bolt or two ensuring the pressure between the two sides there remains the same.
Report Sxx ~ ((load at fracture)/(area of fracture)). Expect perhaps max of annealed 6061-0 (Sy~8ksi, Sult~18ksi) or whatever the basic Al alloy suggests. If lower, this gives an idea of loss by 3D print on axial, at least in this case. A cantilever test, or a perpendicular pull would be interesting to also involve the plane-to-plane bond.
All in all, we've a strange dichotomy at work, with CMTR's & V&P inspection on traditional, but folks pushing for allowed metal print use in similar higher-QA applications, while a-s-s-u-m-i-n-g handbook values, isotropy, and puzzled looks when reminded of an often near-100% welded part without weld inspection. IMO, as yet, 3D print is most often analogous to in-to-near complete sinter, rather uncontrolled (at present), and of most use to low-stress (& smaller) parts. Perhaps with better control, might come to use low-end bulk properties in FEA or hand calcs but, even there, you've usually a in-plane & orthog-plane layering issue plus shape-& order-of-bond issues. I've reservations, at least 'as yet'.
if the upper part is made a little thicker, should be able to go up to 1000 kg: which is very safe for climbers.
Boy that PLA clamp can hold alot
You've got the wrestling theme already - let's see a rematch with each part in the same weight class.
Would it make sense to plot weight versus stretch?
So you compared PLA with low infill and 100% infill metal pieces ?
A PA12 with full infill would have made the results less impressive ?
I would like to see before / after sintering the parts.
brilliant
They’ve come a long way with 3D printing technology
I wish I had that to repaire the loose thread on my iPhone case (for a tripod).
God bless.
That poor PLA never really stood a chance : (
It put up a good fight though!
you should put a strain gauge on it, just use a dial gauge, so you can do a proper stress - strain plot.
4:56 Yes, you've got some leverage onto the part, no wounder it bent
Do metal prints need supports like plastic prints
Not traditional supports like FDM printing does. The metal powder acts as the support, but is not melted by the laser, so it doesn't need to be removed later on.
I'd like to see these tested alongside the same materials except CNCed. I'm interested to know whether which is stronger overall.
I'm working on it. I've got a pile of different materials and methods, including CNC.
Now with the knowledge of that design.
You could try it with thicker plastic at the failure spots.
You have a base line to start with.
that was awesome
What alloys/types of aluminum and stainless did you use?
Listed in description.
@@electrosync 🤦🏼♂️ ah. Cheers
Would be interesting to test the new Carbon Fiber and maybe Titanium 5. It looks like the metal is not fully solid so maybe the new filament type stainless that gets heated will be more dense and thus stronger.
I have some really nice parts printed in onyx with carbon, kevlar and fibreglass reinforcement to try out. Oh, and some titanium parts produced a few different ways. We'll find out soon...
I think what you were trying to say was that you 3D model a carabiner designed by Kong which is a climbing company in Italy and the name of that Carabiner is called frog.
Yes. I have another video on that.
8:02 please add labels to the three curves in the graph :)
2:30 by any chance would that be 'Fish on land' for the background track?
Wow! You have a good ear: Fish on Land (Instrumental Version) - Blood Red Sun
Would be good to see tests against machined parts
Working on it!
Any chance you would share the CAD for the metal print design?
Hi. The link to the STL files is in the description. STEP files are available to Patrons.
Would the strength of the PLA clip be different if it was printed at 100% infill?
I'll be testing that out shortly in a follow up video, including 100% infill vs 999 walls.
You didn’t mention the costs of printing each test item. I would like to see who does this printing so I could contact them for unobtainable parts.
The metal parts were about $500 AUD.
I would be curious of how different methods of 3d printing metal would effect strength.
Post-printing heat-treatment is a huge factor. If it is not heat-treated properly the metal can be extremely brittle.
Layer thickness and laser settings during the print process are important as well.
Re-Run the tests after annealing and/or quenching the parts. Can you get the steel parts re-made with high-carbon steel? I think the differences between steel and aluminum were too narrow. The steel should have much higher tensile strength per unit volume.
I'm working on a follow up video on this including tool steel. I'll need to devise some way of quenching them.
33kg to tare the mug handle off? You can tare it with your own hands?? That's amazing
It all boils down to metallurgy and tribology which still has to be correct for the application. There are many techniques and processes to ensure that you end up with a good part that will function.
Did the metal look porous to you? A big part of the additive metal process are the parameters used, laser power, layer height, powder used, where the parts stress relieved.
yes these are ugly pitted rough parts, dont look at that just buy into the latest craze
I'd be really interested to see what PLA would do at 100% infill.
This bothered me too. Altho the metal wasn't technicly 100% infil either, because of the air bubbles. It wasn't 20% like with the PLA.
ja, not sure why if testing a tensile test, to not have 100% infill
you could make this neat clip from pressed sheet metal as well, giving a stronger part.
Spot on. Follow up video coming soon...
have you thought about heat treating your parts to see if that will help make them stronger
A few have suggested this. Unfortunately my heat treating knowledge/experience is limited to Forged in Fire!
Definitely surprised how close the aluminium and SS were though
Engineer here;
Using the same aluminium piece after it has been subjected to stress testing isn't a true reflection of its material property, though it stands up well in the test, aluminium is famous for its low resilience to fatigue cycles which get worse over time.
That looks like a Kong Frog connector.
Only a limited amount of time until this channel gets a ridiculous amount of viewers
Literally lmfao at that canal bridge test 🤣🤣🤣🤣🤣🤣🤣🤣🤣🤣🤣🤣🤣🤣🤣
well, that PLA+ part looks kinda...hollow... is not the infill, but the wall lines count what makes the pla stronger
The margin between steel and aluminum was much smaller than I expected
If you test with simpler shapes, I think you can compare 3D printed materials with commercially available materials.
Spot on. I'm making a follow up to this video where I use test specimens with a known cross sectional area. This allows me to do some improved calculations.
You should do a video comparing the metal prints to billet milled
Stay tuned...
Where did u get the stainless steel material from?
PCBWay provided me with the 3D printed metal parts.
Surprised Aluminium was so comparable in strength considering all its other advantages, Its just so easy to cut and drill compared to steel and its lightness can easily be the difference between a project being practical and not. Would have liked to see non printed versions for strength comparisons....
If you want to make a thread in a metal you have to make a half/quarter turn forward and then full turn back in order to remove span.
What is that glass thing at 0:39?