3D-WERK 3D prints metal parts on a Fuse1 3D printer using CMF

The German AM service provider 3D-WERK Black Forest GmbH has successfully produced metal parts on a Formlabs Fuse 1+ SLS printer using Cold Metal Fusion (CMF) technology and bound metal powders from HeadMade Materials. By employing Ti6Al4V feedstock, a titanium alloy commonly used in aerospace and medical applications, they demonstrated that high-quality metal components can now be manufactured on an affordable benchtop-sized selective laser sintering (SLS) system. Considering the already very significant Fuse1 global installed base, this achievement marks a breakthrough in making metal 3D printing accessible to a much broader audience.

The innovation lies in the specially designed feedstock, which combines fine metal particles with a thermoplastic binder. When processed on the Fuse 1+, the binder melts and fuses during the SLS process, creating a “green part.” Unlike traditional polymer SLS parts, these green components undergo two additional steps: debinding and sintering. First, the printed object is treated in a solvent bath to remove the binder, leaving behind a porous metal structure. This structure is then densified in a high-temperature furnace, resulting in a precise and fully functional metal part. The final component achieves the strength, accuracy, and durability required in demanding industrial environments, while maintaining a cost structure that is significantly lower than that of conventional metal additive manufacturing processes.

This advancement is particularly noteworthy because the team was able to leverage existing PA12 parameter sets on the Fuse 1+. Thanks to the binder’s similar processing behavior to PA12, only minor adjustments to the machine settings were necessary. This compatibility not only simplifies adoption for users familiar with polymer SLS printing but also highlights the versatility of CMF technology. The process chain remains straightforward, enabling manufacturers to move seamlessly from polymer printing to true metal production without requiring extensive retraining or investment in large-scale industrial equipment.

Cold Metal Fusion itself represents a significant step forward in the evolution of metal additive manufacturing. Developed as a hybrid process, CMF bridges the gap between polymer-based SLS and traditional powder metallurgy. By using polymer-bound metal powders, CMF enables standard SLS printers to produce metal parts. This approach eliminates the need for expensive laser-based metal printers, while still achieving comparable part quality in terms of density, surface finish, and mechanical properties. For industries such as aerospace, automotive, tooling, and healthcare, CMF offers the opportunity to reduce costs, shorten development cycles, and produce parts with geometries that would be impossible to achieve using conventional machining.

The implications of 3D-WERK’s achievement extend far beyond a single printer or material. Headmade Materials GmbH, the company behind the CMF feedstock, supports not only titanium alloys but also other metals,

including stainless steel, tool steel, and Inconel. This flexibility opens the door for manufacturers across different sectors to adopt CMF as part of their production workflows. Whether for lightweight structural components, high-strength tooling, or high-temperature applications, CMF provides a scalable and cost-efficient path to metal additive manufacturing.

Headmade Materials has established a global network of partners in Asia and the United States to support companies interested in exploring the technology. By collaborating closely with industrial partners, they aim to develop tailored process chains that meet specific application requirements, ensuring that every step—from printing to post-processing—is optimized for performance and efficiency.