Engineering Specifications

Advanced Metal Materials & Process Capability

Bound Metal Deposition (BMD) engineered for industrial production. We deliver full-density, functional metal components utilizing BASF Forward AM Ultrafuse ecosystems.

Industrial Alloys

Optimized for high-performance end-use applications, offering the exact chemical composition of conventional steel.

Stainless Steel 316L

An austenitic stainless steel known for its exceptional corrosion resistance and ductility. Ideal for applications exposed to harsh environments, chemicals, or extreme temperatures where maintaining structural integrity is paramount.

Common uses:

Marine hardware, fluid handling components, medical devices.

Stainless Steel 17-4 PH

A martensitic precipitation-hardening stainless steel combining high strength, hardness, and moderate corrosion resistance. It can be heat-treated post-sintering to achieve specific mechanical property tiers tailored to your load requirements.

Common uses:

Aerospace fittings, industrial tooling, high-wear structural parts.

Material Property Reference

Verified technical specifications for our sintered metals, tested in accordance with international ISO standards.

316L As-Sintered

Typical mechanical properties post-sintering without secondary treatments.

Property	Value	Standard
Ultimate Tensile Strength	520 MPa (Typical)	ISO 6892-1
Yield Strength	175 MPa (Typical)	ISO 6892-1
Elongation at Break	40%	ISO 6892-1
Hardness	150 HV10	ISO 6507-1
Density	7.85 g/cm³ (>98% relative)	ISO 3369

17-4 PH (H900 Condition)

Properties after precipitation hardening at 482°C (900°F) for 1 hour.

Property	Value	Standard
Ultimate Tensile Strength	1050 MPa (H900)	ISO 6892-1
Yield Strength	950 MPa (H900)	ISO 6892-1
Elongation at Break	4%	ISO 6892-1
Hardness	400 HV10 (H900)	ISO 6507-1
Density	7.70 g/cm³ (>98% relative)	ISO 3369

Note: Values represent typical material properties and may vary slightly depending on component geometry and orientation during printing.

Material Selection Guide

When to specify 316L: Select 316L when the operational environment involves prolonged exposure to chlorides, acids, or marine conditions. It is the preferred choice for manifolds, pump housings, and applications requiring non-magnetic properties or high ductility over raw tensile strength.
When to specify 17-4 PH: Opt for 17-4 PH for structural components subjected to high cyclic loading, wear, or impact. Its capability to be precipitation-hardened makes it invaluable for custom robotic end-effectors, mechanical linkages, and high-pressure tooling components.

Unsure which alloy fits your needs?

Our engineering team provides complimentary Design for Additive Manufacturing (DfAM) reviews to align your requirements with the optimal material and process.

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The Science of Our Process

We transform polymer-bound metal powder into dense, functional solid steel components through a rigorous three-stage catalytic process.

Digital DfAM & Scaling

Prior to manufacturing, we analyze your geometry. The CAD model is mathematically scaled up across X, Y, and Z axes to precisely compensate for the volumetric shrinkage that occurs during the thermal sintering stage.

Bound Metal Deposition

The oversized "green part" is printed layer-by-layer using a composite filament containing metal powder uniformly suspended in a polymer matrix, resulting in a highly accurate but fragile preform.

Catalytic Debinding

The green part undergoes a catalytic acid vapor process that safely extracts the primary polymer binder, leaving behind a porous "brown part" held together by a secondary backbone binder.

Controlled Sintering

Heated in a pure argon atmosphere furnace to temperatures just below the melting point, the secondary binder burns off and metal particles fuse together, shrinking the part into its final, dense, near-net shape.

Post-Processing & Finishing Capability

Surface Finish Optimization

As-sintered components typically present a surface roughness (Ra) of 4-8 µm. For applications demanding lower friction or aesthetic appeal, we offer mechanical polishing, media blasting, and vibratory tumbling to achieve Ra values below 1 µm.

Precision Machining & Tolerances

Our standard printing tolerance is ±0.5% (with a minimum of ±0.2 mm). Because the final part is pure metal, critical faces, sealing surfaces, or tight-tolerance bores can be CNC machined or tapped post-sintering just like standard bar stock.

Geometric Features & Threads

While internal channels and complex overhangs are easily printed, fine threads are often better suited for post-machining. We routinely print pilot holes and tap them post-sintering to guarantee strong, reliable fastening points.

BMD vs Traditional Manufacturing

Understanding where Bound Metal Deposition fits in the manufacturing landscape.

vs. CNC Machining

Ideal for complex geometries that would require massive material removal or specialized 5-axis setups. BMD incurs zero tooling costs and wastes very little raw material compared to subtractive methods.

vs. Investment Casting

BMD provides cast-like mechanical properties without the need for expensive mold creation. It excels in low-to-medium volume production runs (1 to 500 units) where casting lead times and NRE costs are prohibitive.

vs. LPBF (Laser Powder Bed)

Unlike laser systems, BMD does not suffer from high thermal residual stresses during printing, making it easier to print thick, solid cross-sections safely. It also presents lower facility and powder-handling safety risks.

Applications by Industry

Automotive & Motorsport

From custom exhaust brackets and intake manifolds to lightweight suspension components, BMD allows engineers to iterate rapidly without committing to hard tooling. The ability to print internal cooling channels directly integrates performance benefits unattainable through machining.

Industrial Equipment

Replacement components for legacy machinery can be reverse-engineered and printed in days instead of months. Grippers, custom end-effectors for robotics, and specialized jigs benefit from 17-4 PH's durable, wear-resistant profile.

Precision Engineering

For scientific instrumentation and fluid handling, 316L stainless steel provides the necessary chemical inertness and leak-tight density. Conformal cooling channels and complex internal geometries allow for highly integrated, multi-functional part consolidation.

Why Intent3D

Predictable Shrinkage & Yield

Metal FDM is notorious for difficult shrinkage calculations. We utilize proprietary software profiles and empirical data models gathered from hundreds of furnace runs to ensure your parts scale accurately and sinter predictably, reducing trial-and-error iterations.

Beyond Rapid Prototyping

We treat BMD not just as a prototyping tool, but as a bridge to low-volume manufacturing. Our rigorous quality control and material tracking mirror traditional manufacturing standards.

Technical Transparency

We don't hide the limitations of the technology. If a part is better suited for CNC machining or requires significant DfAM modification, our engineers will tell you upfront before processing the order.

Frequently Asked Questions

How does the strength of BMD parts compare to cast or machined components?

Our fully sintered components achieve greater than 98% relative density, matching or exceeding the mechanical properties of investment casting, and performing comparably to wrought or machined counterparts depending on the specific alloy and heat treatment.

Can 17-4 PH components be heat-treated after sintering?

Yes. 17-4 PH stainless steel parts produced via our process can be subjected to standard precipitation hardening treatments (such as H900 or H1150) to significantly boost yield strength and hardness.

What is the typical lead time for a metal component?

Standard production lead times range from 10 to 14 business days, encompassing printing, debinding, and final sintering. Complex geometries or secondary post-processing may extend this timeframe slightly.

Is it possible to weld or machine the parts after they are printed?

Absolutely. Once the components are fully sintered, they behave chemically and physically like standard metal. They can be machined, tapped, welded, and polished using conventional metallurgical processes.

How do you account for shrinkage during the sintering process?

Bound Metal Deposition involves a significant volumetric shrinkage (typically 15-20%) during debinding and sintering. Our engineering team utilizes advanced DfAM software and proprietary scaling algorithms to predictably oversize the "green" part so the final sintered component meets your dimensional tolerances.

Ready to Evaluate Your Geometry?

Not all parts are ideal candidates for Bound Metal Deposition. Submit your CAD files for a comprehensive engineering review, tolerance assessment, and formal manufacturing quotation.

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