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<p>The potential of copper 3D printing is being explored in a growing number of applications, many of which involve small geometric products and intricate features. Concerning the pure copper AM printability using material extrusion (MEX) (also known as metal extrusion), it stands out as one of the most promising technologies due to the effective coupling of simple 3D printing by extrusion and the subsequent debinding and sintering processes. Despite its user-friendly nature and cost-effectiveness, this method presents limitations especially when dealing with small specimens and features, where geometrical properties and mechanical strength have not been fully explored in the literature. This study investigates the capabilities of piston-fed MEX technology when millimetric parts/features have to be produced in pure copper. The findings indicate that high-dimensional accuracy can be achieved, providing static material resistance in tensile testing that mirrors that of larger parts. In this scale size, the geometric deviations occur at all stages of the design process—from STL to slicing program, on the green and sintered parts—underscoring the importance of managing error propagation. The roles of process parameters, such as layer height and extrusion speed, are outlined and linked to process outcomes. While their impact is significant on dimensional accuracy, surface quality and final porosity, their influence on the produced parts’ microstructure and static mechanical properties proves limited, highlighting the robustness of this production technique and facilitating the optimal parameters selection.</p>

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Advancement on the small-scale fabrication of pure copper parts via material extrusion AM: process performance and quality mapping

  • 期刊论文

  • 出版模式：

    开放获取

  • 发表日期：

    2025年2月21日

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  • Paolo Parenti,
  • Matteo Gavazzoni,
  • Stefano Foletti,
  • Bianca Maria Colosimo

摘要

The potential of copper 3D printing is being explored in a growing number of applications, many of which involve small geometric products and intricate features. Concerning the pure copper AM printability using material extrusion (MEX) (also known as metal extrusion), it stands out as one of the most promising technologies due to the effective coupling of simple 3D printing by extrusion and the subsequent debinding and sintering processes. Despite its user-friendly nature and cost-effectiveness, this method presents limitations especially when dealing with small specimens and features, where geometrical properties and mechanical strength have not been fully explored in the literature. This study investigates the capabilities of piston-fed MEX technology when millimetric parts/features have to be produced in pure copper. The findings indicate that high-dimensional accuracy can be achieved, providing static material resistance in tensile testing that mirrors that of larger parts. In this scale size, the geometric deviations occur at all stages of the design process—from STL to slicing program, on the green and sintered parts—underscoring the importance of managing error propagation. The roles of process parameters, such as layer height and extrusion speed, are outlined and linked to process outcomes. While their impact is significant on dimensional accuracy, surface quality and final porosity, their influence on the produced parts’ microstructure and static mechanical properties proves limited, highlighting the robustness of this production technique and facilitating the optimal parameters selection.