Ampower investigates potential cost savings offered by metal Binder Jetting and FDM

October 25, 2018

Ampower investigates potential cost savings offered by metal Binder Jetting and FDM

Ampower’s new report investigates and compares FDM, Binder Jetting and LB-PBF, as well as MIM (Courtesy Ampower)


Additive Manufacturing consultancy Ampower, Hamburg, Germany, recently published a study investigating and comparing metal Binder Jetting and Fused Deposition Modelling (FDM) with Laser Beam Powder Bed Fusion (LB-PBF) and Metal Injection Moulding (MIM).

In the study, titled ‘Additive Manufacturing with sinter-based technologies’, Ampower identified current cost reductions of approximately 40%, and future cost reductions of over 80% using the newer Binder Jetting and FDM methods of Additive Manufacturing. However, the report also highlighted some disadvantages of these newer technologies, such as limited material properties which could make them unsuitable for the production of highly-loaded components.

In addition, the complex sintering process involved in Binder Jetting or FDM was found to pose further challenges, such as component distortion. Matthias Schmidt-Lehr, co-author of the study and partner at Ampower, explained, “We expect that, especially in the automotive industry, binder technologies will prevail over high-volume cost-cutting as compared to LB-PBF.”

“Limitations on material properties and process risks can be offset by higher volumes and more complex process development,” he continued. “In demanding industries such as aerospace, industry will continue to rely on  laser and electron beam processes. A short-term reorientation is not to be expected in these industries, especially as many OEMs have already set standards here and invested heavily.”

In addition to the principles of cost structure and material properties, the study also presents guidelines for the design of components for production using Binder Jetting. For the study, more than fifty samples from eight equipment manufacturers were evaluated and, in addition to tensile tests and metallographic density analyses, the surface roughness was measured and a CT analysis of the components carried out.


Insight from Ampower’s report was featured in the Autumn/Fall 2018 issue of Metal Additive Manufacturing magazine. Read the full article by Ampower’s Maximilian Munsch, Matthias Schmidt-Lehr and Eric Wycisk for free below.

Download the latest issue of Metal AM magazine

Our latest issue is now available to view online or download in PDF format.

As well as an extensive AM industry news section, this 204-page issue includes articles and reports on:

  • Optimised thermal management in semiconductor fabrication using AI-enabled generative design and Additive Manufacturing
  • Forging a process for mass customisation via metal Additive Manufacturing
  • Bringing it all together: How Materialise is integrating manufacturing and software expertise to shape AM’s future
  • Pedal to the metal at the Digital Manufacturing Centre: Redefining what’s possible for AM in hypercars and beyond
  • The future is Additive Manufacturing – if we take a more holistic view of the design opportunities
  • Building a case for radical collaboration plus quality standards: The pathway to growing the AM industry
  • Distributed manufacturing: Old concept, new relevance, new technology?
  • Design for Additive Manufacturing: A workflow for a metal AM heat exchanger using nTopology (BJT)
  • Taking the holistic view:
    Defining the state-of-the-art in the evolving PBF-LB machine marketplace
  • > More information

Latest news


    Sign up to our e-newsletter, sent weekly to AM professionals and end-users around the world. We'll also let you know each time a new issue of Metal AM magazine is available.

    Discover our magazine archive…

    The free to access Metal Additive Manufacturing magazine archive offers unparalleled insight into the world of metal Additive Manufacturing from a commercial and technological perspective through:
    • Reports on visits to leading metal AM part manufacturers and industry suppliers
    • Articles on technology and application trends
    • Information on materials developments
    • Reviews of key technical presentations from the international conference circuit
    • International industry news
    All past issues are available to download in PDF format, in either single page format or as double-page “spreads” for viewing on large monitors. All downloads are free of charge. Go to archive...

    Connect with us

    Visit our social media channels and sign up to our e-newsletter

    Copy link
    Powered by Social Snap