Metal 3D Printing
- Fastest lead time with no tooling and strong fit for complex geometry.
- Highest unit cost, so it is not cost-effective for large-volume production.
- Best for 1-10 complex structural parts with internal channels or lattice forms.
Metal Low-Volume Manufacturing
Choose the Right MetalProcess Before You Build
Match your part geometry, tolerance needs, material, and finishing requirements to CNC Machining, Sheet Metal Fabrication, Metal 3D Printing, or Rapid Casting before production starts.
SLM Ti6Al4V
CNC 7075-T6
Sheet steel bracket
Investment cast SSGeometry-driven process matching
DFM feedback and lead-time commitment before production starts.
Excellent4.7 out of 5
Find Your Process in 2 Steps
Select your geometry type and precision requirement - the decision tree matches you to the right manufacturing route before you commit.
Step 1
What type of part geometry do you have?
Step 2
Do you have local precision-finishing requirements?
For unspecified areas on the CAD: Tolerance >= +/-0.2 mm · Surface roughness >= Ra 6.3 um
Four Metal Manufacturing Processes
Each process has a distinct geometry fit, cost structure, and performance profile - choosing the right one starts with your part type.
CNC Machining
- Fast lead time, high precision, and wide material compatibility.
- Complex geometry is limited by tool access and material removal time.
- Strong fit for small-to-medium batches of precision mechanical parts.
Sheet Metal Fabrication
- Low cost and fast lead time for simple bent parts and enclosures.
- Structural complexity is limited to flat bends and stamping-like forms.
- Best for brackets, housings, and sheet-type structural components.
Rapid Casting
- Strong cost advantage at higher volumes with complex casting geometry.
- Initial lead time is longest because of pattern and shell preparation.
- Best for medium-to-high volume complex metal parts such as valves or automotive components.
5D Scoring Matrix
Scale 1 (worst) to 5 (best)
Metal 3D PrintingCNC MachiningSheet MetalRapid Casting
Cost Drivers by Process
What Drives Cost in Each Process
Understanding setup cost and unit cost structure helps you plan your production economics before committing.
Metal 3D Printing
Initial Setup Cost
Low
No tooling required - direct from 3D model
Unit Cost
Extremely High
High equipment, metal powder, and post-processing costs
CNC Machining
Initial Setup Cost
Low to Medium
No tooling; requires programming, fixtures, and cutting tools
Unit Cost
Relatively High
Strongly affected by machining time and material removal
Sheet Metal Fabrication
Initial Setup Cost
Low
No tooling; flat-pattern development and bending setup
Unit Cost
Medium
Cost reduction becomes possible as volume increases
Rapid Casting
Initial Setup Cost
High
Requires wax pattern tooling, fixtures, and process development
Unit Cost
Low to Medium
Cost advantage grows significantly with production volume
Technical Specifications by Process
Exact parameters to check against your drawing requirements.
| Parameter | Metal 3D Printing | CNC Machining | Sheet Metal Fabrication | Rapid Casting |
|---|---|---|---|---|
| Tolerance | SLM: +/-0.2%/mm (min +/-0.2 mm)Binder Jetting: +/-0.4%/mm (min +/-0.3 mm) | ISO 2768-m (default)Custom down to +/-0.005 mm | ISO 2768-m (default) | ISO 8062-3 (default) |
| Surface Roughness | Ra 6.3 um (as-built default) | As-machined: Ra 0.4-3.2 umPolished: Ra 0.8 umMirror: Ra 0.2-0.4 um | As-fabricated: Ra 3.2 um | As-cast: Ra 1.6-6.3 um |
| Max Build Size | SLM: 400 x 300 x 400 mmBinder Jetting: 400 x 250 x 250 mm | Up to 4000 x 1500 x 600 mm | Up to 1000 x 1200 mm | Varies by casting process |
| Min Wall Thickness | 0.5 mm | 0.5 mm | 0.6 mm | Typically 1.5 mmDown to 0.8 mm for zinc die casting |
| Standard Lead Time | 2-7 days | 7-15 days | 10-25 days | 15-25 days |
| Best For | Complex structures, internal channels, lattice, low-volume high-performance parts | High-precision, high-strength, functional validation, end-use solid metal parts | Thin-walled enclosures, brackets, chassis, panels; low to medium volume | Medium-to-high volume complex parts; geometric freedom with volume cost advantage |
| Not Ideal For | Tight tolerances without post-CNC finishing | Complex internal geometries inaccessible to cutting tools | Solid parts or complex closed internal cavities | Early-stage designs still changing - tooling changes add time and cost |
Metal Materials at Unionfab
Select by structural requirement, weight target, corrosion resistance, or industry compliance need.
Aluminum Alloys
6061 / 7075 / AlSi10MgLightweight, machinable, widely used for housings, frames, and structural brackets. AlSi10Mg for SLM printing.
AS9100 applicableISO 9001
Stainless Steel
316L / 17-4PHCorrosion-resistant, high strength. 316L for medical and marine. 17-4PH for high-strength printed parts.
ISO 13485AS9100 applicable
Titanium
Ti6Al4VBest weight-to-strength ratio. Aerospace structures, medical implants, and weight-critical parts.
AS9100 applicableISO 13485
Tool Steel
H13 / D2 / S7For tooling inserts, wear-resistant components, and parts that must withstand high mechanical stress cycles.
ISO 9001Industrial use
Copper & Brass
C110 / C360High electrical and thermal conductivity. Connectors, heat exchangers, and electrical components.
ISO 9001EV / Electronics
Nickel Superalloys
Inconel 625 / 718High-temperature strength to 1000°C+. Aerospace turbines, combustion hardware, and extreme-heat industrial parts.
AS9100 applicableISO 9001
Material × Process Matrix
Which process works best for each material - and where the tradeoffs lie.
| Material | Metal 3D Printing | CNC Machining | Sheet Metal Fab | Rapid Casting | Typical Application |
|---|---|---|---|---|---|
| Aluminum (AlSi10Mg, 6061) | AlSi10Mg, 6061 | Best choice | 5052 sheet | Cast Al alloys | Housings, frames, brackets |
| Stainless Steel (304, 316L) | 316L, 17-4PH | Excellent | SUS304, SUS316 | 304, 316 casting | Medical, marine, food-grade |
| Titanium TC4 (Ti6Al4V) | Best route | High cost, slow | Not standard | Investment casting | Aerospace, implants, lightweight |
| Carbon Steel | Maraging Steel | Best route | SPCC, SECC, SGCC | Carbon steel casting | Structural parts, tooling |
| Copper / Brass / Bronze | CuCrZr SLM | Best route | Copper sheets | Brass, bronze casting | Connectors, heat exchangers |
| Nickel Superalloys (Inconel) | Inconel 625 | Difficult, slow | Not standard | Superalloy casting | Turbines, high-temp hardware |
Manufacturing Capability You Can Count On
20+
Years of Manufacturing Experience
Metal 3D Printing, CNC Machining, Sheet Metal Fabrication, and Rapid Casting under one roof.1400+
In-House Machines across 10 Factories
Full in-house production with post-processing coordinated in the same job.ISO 9001 · ISO 13485ISO 14001 · IATF 16949
Quality Certifications
Aerospace, medical, automotive, and industrial quality systems with DFM feedback before production starts.What Happens After You Upload a Metal File
Upload File
CAD file, material preference, quantity, and tolerance requirements.
Instant DFM & Quote
Metal 3D printing supports automated DFM and instant quoting. Other processes are reviewed manually within 24 hours.
Production
Printing, machining, sheet fabrication, or casting, with post-processing handled in the same workflow.
QC & Delivery
Dimensional inspection, surface check, material cert if required, then shipment.
What You Receive After Process Review
Recommended Manufacturing Route
CNC Machining, Sheet Metal Fabrication, Metal 3D Printing, or Rapid Casting confirmed to your geometry, material, and tolerance requirements. Local CNC finishing is added where critical surfaces need tighter control.
Finished Metal Parts
Produced in the confirmed material and process. Surface finish and post-processing are applied where specified, including threads, inserts, heat treatment, anodizing, coating, or polishing.
Quality & Delivery Documentation
Dimensional inspection report when required. Material certificate on request. DFM feedback and engineering notes before production. Labeled batch packing for delivery.
Available Finishing Options
As-machinedBead blastedAnodized Type II / IIIPowder coatedElectropolishedPVD coated
Available Post-Processing
Stress-relief heat treatmentFinish CNC after 3D printingThread tappingInsert installationShot blasting
Documentation on Request
Dimensional inspection reportMaterial certificateFirst-article reportDFM feedbackEngineering notes
Example Outcomes
Aerospace
Titanium drone chassis / structural base
Path: SLM (Ti6Al4V) + bead blast + stress relief
Propulsion
Titanium rocket nozzle extension / combustor component
Path: SLM (Ti6Al4V) + support removal + bead blast + heat treatment
Engineering / Fluid
Power heavy-duty steel hydraulic valve sleeve
Path: SLM (Die Steel / Tool Steel) + CNC turning/milling + surface grinding
READY FOR QUOTE?
Upload Your File
To get an accurate quote, provide: 3D CAD file · 2D engineering drawing (crucial for CNC and casting) · Order quantity · Material preference (e.g., Aluminum 6061, Stainless Steel 304, Titanium TC4) · Intended use: Prototyping / Functional Testing / End-Use Production.
Unionfab is China's Largest 3D Printing Manufacturing Company for Rapid Prototyping and On-Demand Production Parts.
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