Cost-effective metal 3D printing for industry
Production of solid components and structures with controlled porosity using the cutting fractions of metallic powders.
Progresja S.A. offers industrial additive manufacturing of metal elements using the LPBF/SLM method using selected fractions of powders with higher granulation, including fractions above 90 μm derived from gas atomization processes.
The solution is designed for industrial customers who need functional metal parts, short runs, simplified prototypes or porous structures, while also wanting to reduce the cost of manufacturing and make better use of available raw materials.
We manufacture 3D printed metal components in an economical variant, optimized for industrial applications, where the highest resolution typical of high-precision LPBF is not required.
- solid metal alloy elements, designed for functional and technical applications,
- short series of metal parts when the production of a mold, casting or tooling is unprofitable,
- structures with a controlled degree of porosity, designed as a functional feature of the element,
- simplified technological and functional prototypes, used to validate geometry, assembly or principle of operation,
- semi-finished products and components replacing castings or components that are difficult to access in a short time.
In classic LPBF/SLM, finer powder fractions are most often used, selected for high process resolution and very accurate geometry mapping. However, in many industrial applications, this quality is not necessary.
The use of cutting fractions and work on a thicker layer allows the process to be focused on functionality, shorter construction time, better construction economy and reduction of material losses.
More economical to make
A thicker layer can reduce component construction time, which is especially important for prototypes, short runs, and parts with less critical surface accuracy.
Lower material footprint
The process allows for the use of powder fractions, which are often of limited use in standard LPBF applications.
Functionality instead of excessive precision
The technology is a good fit for parts where shape, weight, flow, porosity or delivery time are key rather than the smoothest surface after printing.
The service is designed for businesses that need 3D printed metal parts without the need to run costly tooling processes or a long supply chain.
- short series of technical components, brackets, adapters, brackets, spacers and mounting parts,
- simplified functional prototypes for assembly, flow, thermal or operational tests,
- elements of chemical and process equipment, in which material resistance and the ability to make a short series are important,
- structures with controlled porosity, e.g. filtration, diffusion, flow, absorption or light fillings,
- semi-finished metal products replacing castings or elements that would be too long or unprofitable to deliver by the traditional method.
The technology has been developed for fractions of metallic powders from gas atomization processes. In the current scope, the offer includes mainly selected titanium alloys and stainless steels.
We analyze each query in terms of geometry, expected function, required accuracy, operating conditions and the legitimacy of the use of the economic variant. If a given element requires a classic LPBF with a higher resolution, full qualification or a different manufacturing path, we indicate this at the stage of technological evaluation.
The economical variant with the use of cutting fractions is not a solution for every detail. We do not recommend it as the default path for elements where extremely fine details, very thin walls, minimal surface roughness after printing, tightness without additional qualification or critical safety requirements are decisive.
In such cases, we offer a standard LPBF/SLM process, additional qualification, post-processing or individually selected manufacturing technology.
This is not an offer for companies with their own superficiality. It is an offer to make parts for industry - with the use of technology that allows for the sensible use of such fractions on the process side.
1. Query Analysis The customer sends a 3D model, drawing, description of the function of the element or application assumptions.
2. Technology Assessment We check whether the economic variant with a cut-out fraction and a thicker layer is appropriate for the part.
3. Selection of the design variant We recommend making a solid element, a porous structure or the classic LPBF/SLM process, if the requirements require it.
4. Manufacturing and post-processing We carry out metal 3D printing and agreed finishing operations, cleaning, separation from the platform and auxiliary processing.
5. Documentation and research On request, we can supplement the delivery with basic documentation, measurements, material tests or the scope of inspection agreed with the customer.
The offer is the result of completed research and development works carried out by Progresja S.A. in the project "Sustainable 3D printing: Recovery of titanium from gas atomization waste", co-financed by the European Funds for Silesia 2021-2027.
The project confirmed the possibility of direct use of waste powders from gas atomisation for the additive manufacturing of titanium alloy and stainless steel components. The work included, m.in, powder fractions above 90 μm, mechanical properties of the material and functional features of selected end products.
As a result, today's offer is not a research concept, but an implemented service direction for industrial customers who are looking for economical and more resource-efficient metal 3D printing.
Upload a 3D model, drawing, or feature description of the item. We will check whether the economical variant of LPBF/SLM using superficial fractions is suitable for your application.