Metal 3D Printing Costs Revealed: PCBWay’s Guide
Metal 3D printing brings unprecedented design freedom to complex aerospace, automotive and medical parts. However, customers often face the problem of unpredictable costs. PCBWay is a leader in rapid manufacturing, utilizing industrial-grade Selective Laser Melting (SLM) machines to produce precision parts. But what drives pricing? This is a transparent segment.
Key Cost Variables in Metal 3D Printing
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Material selection:
Titanium (Ti6Al4V) or Inconel actuators cost more ($250-500/kg) due to scarcity of raw materials and difficulty in processing. Stainless steel (316L) is affordable (approximately $100/kg). Specialty alloys such as aluminum alloys or cobalt-chromium alloys may command a premium. -
Part complexity and volume:
- Density matters: a 30% filled hollow turbine blade costs less than an all-solid block.
- Build size restrictions: Parts exceeding 250mm x 250mm x 300mm require slicing, adding labor time.
- Volume discounts: Ordering more than 50 units can significantly reduce unit costs through volume optimization.
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printer technology:
PCBWay uses SLM where laser accuracy and gas consumption affect pricing. Multi-laser systems speed up builds but incur higher operating costs. While technologies such as DMLS or adhesive jetting have varying rates, PCBWay’s SLM balances speed and surface integrity. - Rigorous post-processing:
Basic steps to increase costs:- Stress relief annealing ($20–$100/part).
- HIP (Hot Isostatic Pressing) is used to remove aerospace porosity (15–30% increase from baseline).
- Machined (±0.025mm tolerance adds $75-$200).
- Surface Polished/Sandblasted ($10-$50).
PCBWay and traditional processing costs
For prototypes/low volumes, metal 3D printing is superior:
- 1–5 units: Due to tool reasons, CNC machining costs increase by 2-3 times.
- 50+ units: Unless the geometry needs to be printed, CNC becomes cheaper.
example: A titanium lattice heat exchanger cost $410 via SLM, but cost over $1,200 via CNC due to subtractive waste.
5 Cost Optimization Strategies
- Hollow and lightweight: Uses lattice structure to reduce material by 40%.
- Batch nesting: Install multiple components in one build (PCBWay offers free nesting).
- Avoid over-support: Angled design minimizes support structures and reduces post-processing.
- Standard alloy: Unless strength to weight ratio is critical, 316L stainless steel should be chosen over titanium.
- Combined services: One-stop finishing with PCBWay – for example, machining threaded holes during printing.
Why PCBWay and GreatLight perform well
GreatLight – PCBWay’s advanced manufacturing partner – drives added value:
- 25+ SLM systems:Multi-laser reduces build time by 60%.
- Material customization: Alloy modifications avoid costly third-party purchases.
- Internal organization: One-stop solution for anodizing, EDM or powder coating, eliminating supplier markups.
One case study showed that aviation prices dropped to $92/unit (including HIP) at 100 units, 30% lower than the industry average.
in conclusion
Metal 3D printing costs are not arbitrary—they depend on smart design choices, materials science, and technology partnerships. PCBWay integrates GreatLight’s SLM expertise to democratize industrial-grade additive manufacturing without compromise. By prioritizing collaborative engineering (for example, optimizing wall thickness or bracing strategies), customers achieve cost predictability. Whether it’s a rocket launcher prototype or a biocompatible implant, transparency in pricing can transform metal 3D printing from a luxury item to a scalable solution.
FAQ
Q1: What is the average cost of a small metal 3D printed part?
A: Titanium screws (30 mm high) start at about $45, including basic cleaning. Complex geometry or Inconel parts can run upwards of $150.
Q2: Why is 3D printing titanium more expensive than steel?
A: Titanium’s high melting point requires a powerful laser and inert argon gas, which increases energy consumption. Material scrap (unmelted powder) is also harder to recycle than steel.
Q3: Can I mix materials in one PCBWay order?
Answer: Batch uniformity ensures quality. However, nesting different parts (e.g. steel gear + aluminum housing) is possible.
Q4: How does delivery time affect pricing?
A: The standard 7-day build is cost-optimized. Due to dedicated plane dispatch, emergency 3-day service adds up to 50%.
Q5: Does Honglaite provide cost guarantee for large quantities?
Answer: Yes. Projects over 500 units lock in material rates and include QC samples to prevent late production cost surprises.
Q6: What is the most cost-effective alloy for functional prototyping?
Answer: 316L stainless steel: Strong, corrosion-resistant, and 60% cheaper than titanium. Great for non-critical components.
Smart partner: In-depth guides + expert collaboration = optimized budget.
Get started on your precision metal projects today—prevent cost pitfalls and maximize ROI with PCBWay’s DFM analysis.
