Raise3D MetalFuse 3D Printing System Overview

Updated Jun 30, 2022 588

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.

 

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
  • Atmosphere Partial-pressure sintering (vacuum-enabled)
  • Catalyst Raise3D’s Debinding Fluid or Nitric Acid Liquid
  • Connectivity WLAN, Ethernet
  • Cooling system Industrial chiller with flow rate of 1.6 m³/h
  • D200-E debinder
  • Exhaust treatment Activated carbon adsorption facilities
  • Filament diameter 2.85 mm
  • File formats STL, OBJ, 3MF, OLTP
  • Forge1 3D printer
  • Heating element Silicon molybdenum rod
  • Layer thickness 0.1–0.25 mm
  • Materials supported Ultrafuse 316L, Ultrafuse 17-4PH
  • Max. build plate temperature 120 ℃
  • Max. catalyst volume of storage tank 2 L
  • Max. debinding speed 1.55 mm/h
  • Max. gas flow rate 5 L/min
  • Max. heat load 12.5 kW
  • Max. nozzle temperature 300 ℃
  • No. of print heads Dual-head with electronic lifting system
  • Nozzle diameter 0.4 mm (Default), 0.6 / 0.8 mm (Available)
  • Onboard control 7" touchscreen display
  • Operating ambient temperature 15–30 ℃, 10–90% RH non-condensing
  • Operating system(s) Microsoft Windows, macOS, Linux
  • Peak internal temperature 1450 °C
  • Power requirements 220–230 V AC, 50 Hz, Single Phase, 16 A / 3.5 kW Peak Draw
  • Print head travel speed 30–150 mm/s
  • Printing modes Normal, Quality, High Resolution, Mega-Quality, Variable Resolution
  • Protect gas type Argon, Nitrogen
  • Remote software ideaMaker Metal, RaiseCloud
  • S200-C vacuum sinter
  • Sinter run time About 20 hours
  • Sintering workload 5832 cm³
  • Software ideaMaker Metal
  • Work holding Adjustable multi-level trays (6 positions)
  • Workload envelope 200 x 200 x 200 mm
  • Build volume Single extruder print — 300 x 300 x 300 mm; Dual extruder print — 255 x 300 x 300 mm
  • Technology FFF
  • Working Temperature 150 °C for Debind Fluid, 130 °C for Nitric Acid Liquid
  • Outer dimensions 620 x 626 x 1390 mm
  • Power Requirements 380–400 V AC, 50 Hz, 3 Phase (5 wire), 40 A / 27 kW Peak Draw
  • Weight 800 kg

 

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.

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