Introducing Metal Printing on Ultimaker

Ultimaker is the most robust, user friendly and precise FFF Machine in the Desktop, Jig, Fixtures and Tools space.

Ultimaker's Open Filament system allows printing using an innovative solution for Metal Printing.

Using The Virtual Foundry's Filamet™ anyone can now print in Metal. Metal Filamet™ contains more than 80% metal incased in plastic binder. The printing is similar to PLA or ABS Printing.

After printing, the part can be lightly polished and corrected. Then the part can be Sintered in a Kiln at specified temperature using sintering techniques to convert the Filamet™ into 100% metal part.

Metal Filamet™ Trial Pack

Filamet™ Pack Included Price
per Set
Stainless Steel 316 Pack (Graphite) FilaMet™ 0.50Kg + Warmer + Refactory (.5Kg)
Rs.33,999.00
Stainless Steel 316 Pack (Al2O3) FilaMet™ 0.50Kg + Warmer + Refactory (1Kg)
Rs.35,999.00
Bronze Pack (Magic) FilaMet™ 0.50Kg + Warmer + Refactory (1Kg)
Rs.25,999.00
Bronze Pack (Al2O3) FilaMet™ 0.50Kg + Warmer + Refactory (1Kg)
Rs.26,999.00
Copper Pack (Magic) FilaMet™ 0.50Kg + Warmer + Refactory (1Kg)
Rs.24,999.00
Copper Pack (Al2O3) FilaMet™ 0.50Kg + Warmer + Refactory (1Kg)
Rs.25,999.00
Note:
  • Price is tentative and subject to change without notice.
  • Price is exclusive of GST and Shipping.
  • Part Shrinkage will occur during sintering - Shrinkage may depend on filamet type ranging from 7% onwards
  • Filaments sizes might not be in stock. Please contact us at info@novabeans.com for availability
  • Filament specification might change without notice.
  • Consumables once sold will not be returned / refunded.

Metal Filamets™

Filamet™ Radiation Shielding without Sintering FilaWarmer Temp Diameter
(mm)
Spool Size
(Kg)
Price Catalog Downloads
Aluminium Filamet™ - Not Required 1.75mm
0.50kg
0.25kg
Rs.35,999.00
Rs.20,999.00

Slicer Profiles

Stainless Steel 316L Filamet™ - 60°C 1.75mm
2.85mm
1Kg
0.50kg
0.25kg
Rs.40,999.00
Rs.22,999.00
Rs.10,999.00

Slicer Profiles

Copper Filamet™ Yes 45°C 1.75mm
2.85mm
1Kg
0.50kg
0.25kg
Rs.18,999.00
Rs.11,999.00
Rs.6,999.00

MSDS


Slicer Profiles

Bronze Filamet™ - 45°C 1.75mm
2.85mm
1Kg
0.50kg
0.25kg
Rs.28,999.00
Rs.15,999.00
NA

Slicer Profiles

High Carbon Iron Filamet™ - Not Required 1.75mm
2.85mm
1Kg
0.50kg
0.25kg
Rs.21,999.00
Rs.12,999.00
Rs.8,999.00

Slicer Profiles

Tungsten Filamet™ Yes Not Required 1.75mm
2.85mm
1Kg
0.50kg
Request for Quote
Customised Filamet™
{Filamets manufactured on request}

Materials List:
Alloy Base Typical Chemistry Composition Order Name
Cobalt Co-23Cr-10Ni-7W-4TaCo
Cobalt Co-28Cr-6Mo-0.2C-0.2NCoCr
Iron Fe-14Cr-4Ni-4Cu-0.3Nb 15-5
Iron Fe-16Cr-4Ni-3Cu-1Si-0.25Nb 17-4
Iron Fe-17Cr-12Ni-3Mo 316
Iron Fe-18Ni-9Co-5Mo-1Ti Maraging Steel
Nickel Ni-12Co-7Cr-6Ta-6Al-5W-3Re-2Hf-2Mo-0.1C 142
Nickel Ni-22Cr-14W-2Mo 230
Nickel Ni-10Co-10W-8Cr-6Al-3Ta-1Hf-1Ti-0.6Mo-0.2C 247
Nickel Ni-20Cr-10Co-9Mo-2Ti-1.5Al 282
Nickel Ni-22Cr-12Co-9Mo-1Al-0.6C 617
Nickel Ni-22Cr-9Mo-Nb+4Ta 625
Nickel Ni-19Cr-18Fe-Nb+5Ta-3Mo-1Ti 718
Nickel Ni-16Cr-9Co-3Al-3Ti-3W-2Mo-2Ta-0.9Nb-0.1C 738
Nickel Ni 99 min 914
Nickel Ni-22Cr-10Co-4Ti-2W-2Al-1Ta-1Nb-0.1C 939
Nickel Ni-22Cr-19Fe-9Mo-2Co-0.5W-0.1C X
Titanium Ti-6Al-4V, grade 5 64-5
Titanium Ti-6Al-4V, grade 23 (or ELI) 64-23
Titanium Ti-48Al-2Nb-2Cr 4822
Titanium Ti-6Al-2Sn-4Zr-2Mo 6242
1.75mm
2.85mm
0.50kg
0.25kg
Price on request
Note:
  • Price is tentative and subject to change without notice.
  • Price is exclusive of GST and Shipping.
  • Part Shrinkage will occur during sintering - Shrinkage may depend on filamet type ranging from 7% onwards
  • Filaments sizes might not be in stock. Please contact us at info@novabeans.com for availability
  • Filament specification might change without notice.
  • Consumables once sold will not be returned / refunded.

Filament Warmer

Price : Rs.10,899.00 ++
Note: Price is exclusive of GST and Shipping

Filamet™ has an exterior plastic coating that encases and protects the metal material. This plastic keeps the memory of its shape on the spool. As Filamet™ passes through the warmer, the memory of the Filamet™ is reset and prints with ease.

The FilaWarmer comes pre-programmed to 60°C and is adjustable as per the requirement. FilaWarmer should be hung so that both the warming tube of the warmer and the entry tube of the printer lines us. The Filaments are very fragile and will snap with slight bends so sharp bends should be avoided during filament movements.

Filament Temperature Table

Filament TypeTemperature
°C
Stainless Steel 316L60°C
Bronze45°C
Copper45°C

How to print FilaMet™

What is the difference between 3D printing PLA and your metal filaments?

Due to its high metal content, Filamet™ will inherently break more easily than standard PLA.


What can I do to successfully print metal filaments?

Our metal filament: Filamet™ is easy to use as long as you follow some basic instructions.

  • Place the spool so that pull and friction are reduced as much as possible.
  • Use a FilaWarmer to ease the path from spool to printer.
To report any issues with Filamet™ after trying a FilaWarmer, please contact info@novabeans.com


What temperature will work the best?

Temperature: 401-419°F (205-215°C)


What is the Bed Temperature ?

Set print bed to 122°F (50°C) (optional).


Any tips that would help in the 3D metal printing process?

Put a layer of blue painters tape on the print bed. Filamet™ has great adhesion to the bed. For easier removal of prints, heat the print bed before removing the print.


What is the printing speed for 3D printing with metal filament: Filamet™

Speed: 1800mm/min to start.


Any tips that would help in the 3D printing process with metal filaments?

Filamet™ prints just like any other PLA 3D printing filament, with one exception... start slow. Rushed prints are the most common cause of rough prints. Because Filamet™ is more than three times heavier than plastic filament, three times more energy is needed for print heads to heat the material, often taking more time.

In DIY machines some users have added larger heaters to their print heads in order to get higher print rates.

With experience, prints can be faster, but for a quick win on a first try, start at about 2000mm/min. Increase to normal speed as experience is gained.



What is the layer height for printing with metal filament: Filamet™?


Layer Height: Many slicers lay down an extra wide first layer to get good adhesion to the bed.

This is not a problem unless the first layer is very thin. With traditional PLA, it will simply squeeze out at the sides.

Filamet™ is more viscous which slows this process. If the printer nozzle seems clogged, it may be that the nozzle is too close to the bed on the first layer. Once dialed in, some users are printing down to a layer height of .1mm.


What type of nozzle is needed to print with metal filament: Filamet™?

For Copper, Bronze and Stainless Steel 316L Filamet™ - use a .6mm Std Stainless Steel Nozzle
For High Carbon Iron Filamet™ - use a .8mm or larger hardened CC-Red or Ruby nozzle


Where should the reel be placed when printing with metal filament?

Reel Placement: Reducing friction and pull on Filamet™ during printing is important. Try hanging the reel just above the printer. Any way to reduce friction and pull will greatly reduce chances of breakage during printing.


Is there any solution that can improve the 3D metal printing process?

Use a FilaWarmer when printing with our metal filament: Filamet™. Our metal filaments have an exterior plastic coating that encases and protects the metal material. This plastic keeps the memory of its shape on the spool.
As Filamet™ passes through the warmer, the memory of the Filamet™ is reset and prints with ease.


Filament Warmer Temperature Table

Filament TypeTemperature
°C
Stainless Steel 316L60°C
Bronze45°C
Copper45°C

How to sand and polish metal filamet™

With heat, Filamet™ becomes clay-like. It can be carved, re-sculpted, pieces can be added and seams smoothed. Important! Constant movement is necessary when sanding to avoid unintentional melting. Experimenting is worthwhile.

Needle file
To make print lines vanish, sand the surface even. The loose particles from sanding are smashed into the print line gaps with the heat from the friction, fixing them in place. This step is complete once the entire print’s surface is smooth and even.

Sandpaper or 3M Radial Disc
Start with 120 grit sandpaper or 80 grit 3M Radial Disc, and go over every part of the print. The matte surface will become shiny as finer grits are used. Complete the entire surface of the print before moving to the next grit. The Virtual Foundry recommends using 4 grits with 3M and 6 or 7 grits with sandpaper. A nice shine can be achieved with less, but the mirror shine comes closer to the 7, ending around 3000 grit. After sanding, rub the print down with some flannel or a sunshine cloth to clean off loose particles. A mirror shine should be evident at this phase, even before the last step.

Sewn Buff and Zam
Place sewn buff on a rotary tool, then liberally apply zam to the buff and to your print. The print will melt if it gets too hot, so it is critical to keep the buff moving and continue to apply zam liberally. It may be useful to practice this step on a simple print or a “failed print.”


Sintering Furnaces

Furnaces used to sinter objects printed with Filamet™ should meet the requirements below:

Filamet™ Max Furnace Temp. Sintering Temp. Furnace Atmosphere Refactory Programmable
Copper & Bronze 2012°F (1100°C) Bronze: 1590°F (865.6°C)
Copper 1801.4°F (983°C)
Open Magic Powder Yes
Copper & Bronze 2012°F (1100°C) Vacuum or Inert Al2O3 Mixed Yes
Stainless Steel 316L 2552°F (1400°C) SS316L : 2192°F (1200°C) Vacuum or Inert Al2O3 or Graphite Powder Yes
Note: Furnaces can vary in temperature by 100°F (37.8°C) from the furnace readout which can adversely affect results. Test furnace temperature with an independent thermometer.
When a vacuum or inert environment furnace is used, Magic Black Powder cannot be used. Replace the powder with a suitable refractory to support the print's shape. TVF recommends powdered graphite.

Sintering Furnaces Packages

We offer High capacity sintering furnaces with a range of chamber sizes. All of these kilns are suitable for 3D Metal Printing Filaments and materials created by The Virtual Foundry.

The high temperature furnace is delivered as a package and includes:

  • Pre-programmed controller
  • Vacuum pump
  • 1kg Al2O3 refractory ballast
  • 0.5kg Powdered Graphite refractory ballast
  • Crucible
  • Sintering Furnace Manual
  • Gloves and Tongs
  • All units have a maximum temperature of 1400°C (2552°F).

Note: For complete firing instructions, see the Sintering Techniques section.



Sintering Furnace Technical Details

Chamber Size Unit Size Unit Weight Price
Option 1 100mm x 100mm x 100mm (3.9”x 3.9”x 3.9”) 670mm x 670mm x 1115mm (26.4”x 26.4”x 43.9”) 138kg (304lb) Request for quote
Option 2 150mm x 100mm x 100mm (5.9”x 3.9”x 3.9”) 735mm x 695mm x 1160mm (28.9”x 27.4” x 45.7”) 150kg (331lb) Request for quote
Option 3 200mm x 150mm x 150mm (7.8” x 5.9” x 5.9”) 775mm x 755mm x 1260mm (30.5” x 29.7” x 49.6”) 179kg (395lb) Request for quote
Option 4 300mm x 200mm x 200mm (11.8” x 7.8 x 7.8”) 860mm x 770mm x 1325mm (33.9” x 30.3” x 52.2”) 227kg (500lb) Request for quote
Option 5 400mm x 300mm x 300mm (15.7" x 11.8” x 11.8”) 1025mm x 1000mm x 1650mm (40.4” x 39.4” x 65.0”) 372kg (820lb) Request for quote
Note: Furnace specification can change without notice. Please contact us at info@novabeans.com for more details.

Sintering Refractory

Sintering Refractory are used during firing to support the part during the shrinking (7% onwards) and firing process. The Part must be completely covered in Refractory to ensure good sintering. Refractory materials are of primarily four types as per chart below:

Refractory Filamet™ Atmosphere Pack Size Cost
Magic Powder Copper & Bronze Open 1 Kg. Rs.2,599.00
Al2O3 Mixed Copper & Bronze Open 1 Kg. Rs.3,299.00
Al2O3 White Stainless Steel 316L & High Carbon Iron Vacuum or Inert 1 Kg. Rs.6,299.00
Graphite Powder Stainless Steel 316L & High Carbon Iron Vacuum or Inert 0.50 Kg. Rs.3,299.00

Download Magic Powder Mixing Video


Download Sintering Video


Sintering Techniques

Sintering the printed part is the last step before finishing or polishing the part. Sintering can be done in two ways:

(1) For Copper and Bronze : In Open Furnace using Magic Powder

(2) For Other Materials : In Vacuum / Inert Environment using Al2O3 Powder or Graphite Powder as supports

Filamet™ Sintering Temp. Furnace Atmosphere Refactory Programmable
Copper & Bronze Bronze: 1590°F (865.6°C)
Copper 1801.4°F (983°C)
Open Magic Powder Yes
Copper & Bronze Vacuum or Inert Al2O3 Mixed Yes
Stainless Steel 316L SS316L : 2192°F (1200°C) Vacuum or Inert Al2O3 or Graphite Powder Yes
Note: Furnaces can vary in temperature by 100°F (37.8°C) from the furnace readout which can adversely affect results. Test furnace temperature with an independent thermometer.
When a vacuum or inert environment furnace is used, Magic Black Powder cannot be used. Replace the powder with a suitable refractory to support the print's shape. TVF recommends powdered graphite.
Detail Process as below :

Sintering in an Open Environment (Copper and Bronze Filamet™ Only)

Items Needed
  • Refractory Container (Crucible)
  • Magic Black Powder
  • Water
  • Small paint brush

Mix the Magic Black Powder (MBP)

Start with a mixture of 1.8 parts MBP to 1 part water and adjust as needed. The mixture should be a bit on the runny side but have a thicker consistency than water. Starting with a thinner mixture allows more time to paint on the first layer before the MBP sets up too much.

Check the Magic Powder Mixing Video here.


Prep the Print
Manually paint a layer of the MBP mixture onto the print, carefully covering all surfaces. This coat grabs all the detail of the print and makes a mold that holds the print’s shape while firing. During the painting process, the MBP is thickening in the Crucible (metal cylinders work best as Crucibles). Put the print into the MBP while it's just barely thick enough to suspend it. If it’s too thick, air pockets and bubbles can occur and create deformities in the fired print.

Firing
Place the Crucible in the furnace and begin the firing cycle.

  1. Start at room temperature.
  2. Ramp temp at full speed to 150°C (302°F) and hold for 1 hour, 15 minutes.
  3. Over the course of 200 minutes, ramp temp to 400°C (752°F). Do not hold.
  4. Over the course of 180 minutes, ramp temp to 983°C (1801.4°F) for Copper or 865.6°C (1590°F) for Bronze and hold for 240 minutes.

Tip
Once the container passes 315°C (599°F), minimize its exposure to oxygen (i.e., do not open the furnace, make sure peepholes are plugged, etc.).

Quench
This step ends firing and cools the print. While the print sinters, prepare a 1-2 gallon metal container of water. When the sintering time is up, use tongs and heat resistant gloves to remove the print container from the furnace and slowly and gradually place directly into the water. The water will hiss and bubble as the project cools, and MBP will disintegrate. Retrieve the object from the water when cool, after about 3-5 minutes.

Check the Sintering Video here.


Important Note
The Magic Black Powder closest to the print should be dark gray. If it is white, troubleshooting is needed to eliminate oxygen. Try sealing the container with stainless steel tool wrap.

Initially, the print will be dark: this is a very thin surface layer. Much of it can be removed by pickling, but sandblasting, fine steel wool or tumbling will also get the job done. The Virtual Foundry recommends 3M Radial Bristle Discs.

Every situation is different and you may need to modify your sintering times and temperatures based on your application and use of our materials. These are general guidelines to get you started.

For first trials, plan for 7% shrinkage of the part overall through the sintering process.

Tip: The mechanical properties of the final product are directly related to how long the print is held at the sintering temperature. If the end product is powdery and brittle, it’s under-sintered. If the print looks like old wrinkled fruit, it’s over-sintered. Eliminate exposure to oxygen to avoid failure due to oxidation.


Print is ready for finish work!

Sintering in a Vacuum or Inert Environment (All Materials)

Items Needed
  • Crucible: Firing Container
  • Refractory Materials (any one type)
    • Magic Black Powder
    • Powdered Graphite
    • Mixed Al203 for Copper and Bronze
    • White Al2O3 for Stainless Steel 316L and High Carbon Iron
      (use a mix of graphite and Al2O3 or use Al2O3 alone)
  • Water
  • Small paint brush

Preparation
Place the object in the refractory, ensuring the entire print and all surfaces are completely covered and any protruding areas are fully supported. The print must be fully surrounded by the refractory. Ensure that at least 10mm of refractory insulates the print from the walls of the crucible.

Fire
Place the Crucible in the furnace and begin the firing cycle.

Firing in Inert / Vacuum for Copper or Bronze
Place the Crucible in the furnace and begin the firing cycle.

  1. Start at room temperature.
  2. Over the course of 200 minutes, ramp temp to 205°C (401°F). Do not hold.
  3. Over the course of 180 minutes, ramp temp to 400°C (752°F). Do not hold.
  4. Over the course of 180 minutes, ramp temp to 983°C (1801.4°F) for Copper or 865.6°C (1590°F) for Bronze and hold for 440 minutes.
  5. End cycle and let furnace cool to ambient temp until Crucible can be removed by hand.

Firing in Inert / Vacuum for Stainless Steel 316L
Place the Crucible in the furnace and begin the firing cycle.

  1. Start at room temperature.
  2. Over the course of 200 minutes, ramp temp to 205°C (401°F). Do not hold.
  3. Over the course of 180 minutes, ramp temp to 400°C (752°F). Do not hold.
  4. Over the course of 180 minutes, ramp temp to 1225°C (2237°F) and hold for 240 minutes.
  5. End cycle and let furnace cool to ambient temp until Crucible can be removed by hand.

Firing in Inert / Vacuum for High Carbon Iron Filamet
Please visit us again as this process is still under progress....

Note
Every situation is different and you may need to modify your sintering times and temperatures based on your application and use of our materials. These are just general guidelines.




Important Note

For first trials, plan for 7% shrinkage of the part overall through the sintering process.

Tip: The mechanical properties of the final product are directly related to how long the print is held at the sintering temperature. If the end product is powdery and brittle, it’s under-sintered. If the print looks like old wrinkled fruit, it’s over-sintered. Eliminate exposure to oxygen to avoid failure due to oxidation.


Print is ready for finish work!