Raise3D MetalFuse 3D Printing System Overview

by Anabelle Yearsdon

Updated Jun 30, 2022 12245

From this article, you will learn about a new professional MIM (Metal Injection Molding) 3D printing system — MetalFuse by Chinese company Raise3D. Let’s shed some light on its main peculiarities and technical specifications.

Pros and cons

Complete solution for the production of high-quality metal parts
Environmentally friendly, energy-efficient, and safe printing
Easier and safer material handling compared to powder-based metal 3D printing
Time and cost-efficient solution for single parts and small-to-medium batch manufacturing
Simple and convenient operation
Dedicated ideaMaker Metal software is specially optimized for metal 3D printing, debinding, and sintering

Limited number of available filaments
Not suitable for large-volume manufacturing

Video

First look

MetalFuse is a complete solution based on indirect metal printing technology. It consists of the Forge1 metal filament 3D printer, the D200-E catalytic debinding machine using oxalic acid, and the S200-C vacuum sintering furnace. This impressive combination enables cost-effective manufacturing of high-quality metal parts comparable to wrought iron in its mechanical properties.

The complete solution is ideal for economical production of single metal parts as well as small-to-medium item batches. On top of that, the MetalFuse is energy-saving and more environmentally friendly compared to traditional CNC and SLM processes.

Specifications

Raise3D MetalFuse

Dimensions 1434 x 1137 x 1974 mm

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Operating principle

On top of the 3D printer, the MetalFuse system includes the D200-E cleaning station and the S200-C sintering furnace, which are used for post-processing of the so-called “Green parts”. The process is based on BASF’s know-how in metal injection molding.

The catalytic debinding process used by MetalFuse is based on oxalic acid. It reduces binder removal time and allows increasing the final part density up to 97%, which is 52% more compared to products obtained by traditional debinding methods. Besides, this technology works even with titanium and copper.

Overall, the procedure is completely safe, easier than nitric acid treatment, and faster than solvent and thermal debinding.

Highlights

Build process

The Raise3D Forge1 is equipped with two extruders with the maximum hotend temperature of 300 ℃. Another benefit of the printer is its decent build volume — a cube with an edge length of 300 mm — as well as the layer thickness of 0.1–0.25 mm.

Materials

The Raise3D MetalFuse utilizes BASF metal filaments — UltraFuse 316L and UltraFuse 17-4 PH — as consumables. These composite filaments consist of 80–90% stainless steel of the corresponding grade and 10–20% resin binder. BASF plastics ensure excellent printing repeatability and high productivity.

Control and connectivity

All the MetalFuse system devices are equipped with large sensitive touchscreens featuring a carefully designed interface. Selecting the required profile and working with necessary files takes just a few clicks.

Software

To prepare digital models for printing, Raise3D offers a special version of the ideaMaker software, namely the Metal Edition. The program offers special templates optimized for metal printing as well as smooth sintering and debinding processes. In addition, it provides simplified slicing algorithms for a user-friendly experience.

Print samples

As of the moment, the MetalFuse system is expected to provide accurate calibration, precise printing, and decent quality surface for ready parts. Combined with several nozzle size options (0.4, 0.6, and 0.8 mm), the solution empowers huge possibilities in end-use parts production.

Bottom line

With the above mentioned features considered, the MetalFuse 3D printing solution is highly recommended for applications such as small-scale manufacture, as it is clearly aimed at reliable performance, smooth operation, low overhead costs, and efficient batch production of high-quality items with outstanding characteristics.

FAQ

Which filaments are compatible with the MetalFuse?

The Raise3D MetalFuse is compatible with Ultrafuse metal filaments from BASF Forward AM, namely Ultrafuse 316L and Ultrafuse 17-4 PH, which contain up to 90% metal particles and the polymer binder which is completely removed during debinding and sintering, leaving a high-quality full-metal part with excellent mechanical and physical properties.

What are the advantages of using oxalic acid for the debinding process?

Unlike most FDM metal 3D printing solutions, that use solvent or thermal debinding, the MetalFuse D200-E uses oxalic acid catalytic debinding in an argon-nitrogen atmosphere — a safe and environmentally friendly method with a high debinding rate (over 1 mm/h). The process allows for significant (up to 60%) time saving, compared to solvent or thermal debinding, and increases the final part’s density to up to 98% of that of the wrought iron.

What is the sintering process needed for?

Sintering is the final step of FDM metal manufacturing. The S200-C vacuum sintering furnace is used for removing the secondary binder at the temperature just below the metal melting point, so the part can obtain its final properties, such as hardness and strength. The S200-C features low gas and energy consumption and ensures fast sintering, making for a highly efficient production cycle.

Can the Forge1 print with support structures?

The Forge1 is equipped with a dual extruder allowing printing support structures for parts with complex geometries. BASF offers Ultrafuse Support Layer material designed specifically for the use with Ultrafuse metal filaments. A thin layer of this material is printed between the support and the main part, facilitating support removal after sintering and preventing part deformation during debinding and sintering processes.

Anabelle Yearsdon

Updated Jun 30, 2022

About the expert

A linguist by profession and 3D enthusiast by passion. Spirited researcher of existing and new AM technologies, inquisitive tester of various devices, and a true connoisseur of creative ways. In addition to digital manufacturing, Ana enjoys learning new things, cooking for her loved ones, and chilling in video games.