Blog

Nov 04, 2024

Using a Green Laser Facilitates 3D Printing of Pure Copper and Copper Alloys - 3Dnatives

Metal additive manufacturing is finding its way into more and more industries, from aerospace and marine to electronics and automotive. It enables the design of more complex, lightweight and durable

Metal additive manufacturing is finding its way into more and more industries, from aerospace and marine to electronics and automotive. It enables the design of more complex, lightweight and durable parts. Copper’s excellent electrical and thermal conductivity, resistance to atmospheric and marine corrosion, ductility and toughness make it one of the most widely used metal materials.  

However, manufacturing with copper presents specific challenges, especially when using traditional laser powder-bed fusion (LPBF) techniques. Pure copper has a very low absorption rate for infrared lasers—less than 10%. As a result, high-power infrared lasers can lead to excessive vaporization and spattering, which negatively impact the final part. These effects include reduced material density, increased porosity, and diminished thermal and electrical conductivity. Additionally, when the reflected light is over 90%, it can damage the 3D printer’s optical components. 

IGBT Heat Sink Copper Base Plate , Pure Copper

This is where Addireen, a Chinese manufacturer, stands out. With cutting-edge green laser technology, Addireen’s industrial machines overcome the limitations of infrared lasers. Their machines can produce copper parts with a density of 99.8% and a minimum wall thickness of 0.08mm, significantly enhancing the quality and precision of the components, unlocking copper’s full potential in metal additive manufacturing. 

A green laser has a much higher absorption rate on copper than an infrared laser. As the graph below shows, the green laser is more effective at melting copper and its alloys, gold, platinum, and other materials with high reflectivity and thermal conductivity. Therefore, LPBF technology based on green lasers can achieve high-quality and efficient 3D printing of pure copper and copper alloys. 

Absorption rate of different metals

The high-power single-mode continuous fiber green laser Addireen adopts has the advantages of shorter wavelengths, high beam quality, high stability, and finer focused spots. It offers greater forming efficiency, better quality, higher printing resolution, and a larger process window for additive manufacturing of pure copper, copper alloys, gold, and platinum. Additionally, green laser 3D printing also expands the range of materials that can be printed using LPBF technology. 

Addireen has launched green laser metal 3D printing devices (XH-M160G, M350G, M100G) that achieve high-efficiency, high-quality, and high-precision 3D printing of pure copper parts. The metallographic images are shown below, demonstrating the ability to withstand water pressures greater than 5 MPa, with conductivity close to 100% IACS and thermal conductivity of approximately 390 W/m·K. The minimum wall thickness can reach 0.08 mm.

Metallographic Image of Pure Copper Printed Parts

Addireen’s green laser metal 3D printing equipment has been widely applied in aerospace, new energy vehicles, semiconductor heat sink components, induction heating coils, and high-speed communication devices. Some application examples are shown in the pictures.

Engine nozzle model  printed in CuCrZr

Founded in 2023, Addireen has pioneered green laser-based metal 3D printing in China. With nearly 18 years of experience, the team has developed advanced technologies like short-wavelength and multi-wavelength lasers for precise printing of highly reflective, refractory, and conventional metals. 

High-Frequency Induction Heating Coil , Pure Copper

Addireen offers three models, all equipped with green lasers, capable of printing parts with 99.8% density and a minimum wall thickness of 0.08mm. The print volumes range from Ø100 x 100mm to 350 x 350 x 500mm, meeting diverse needs. The XH-M100G, ideal for precious metals like silver, gold and platinum, achieves laser spot sizes as small as 15 microns for intricate structures, while the M350G is designed for high-volume production. 

Addireen’s green laser solutions have been tested and adopted in numerous sectors. This includes in aerospace, energy, communications and transportation.  

The range of solutions from Addireen

Addireen concludes: “Green laser 3D printing not only enables efficient and high-quality printing of pure copper and copper alloys but also expands the range of materials that can be printed using LPBF technology. It provides an ideal solution for highly reflective and difficult-to-melt materials, while also enabling more efficient and precise printing of conventional metal materials.” Find out more about Addireen HERE.  

Ultra-Thin Wall Heat Dissipation Fins  printed in CuSn10 

What do you think of Addireen’s solutions? Let us know in a comment below or on our LinkedIn, Facebook, and Twitter pages! Don’t forget to sign up for our free weekly Newsletter here, the latest 3D printing news straight to your inbox! You can also find all our videos on our YouTube channel.

*Credits of all the pictures: Addireen

The flexibility in design and customization, the elimination of casting molds and the low material…

It would not be hyperbole to say that the U.S. Navy has quickly become one…

The additive manufacturing sector continues to advance thanks to the talent and motivation of the…