Why the Right Methods, Equipment & Processes Matter

In copper powder additive manufacturing, even the highest-quality powder can fail without proper execution. The trio of manufacturing methods, specialized equipment, and streamlined processes determines whether your copper parts achieve 99.96% density, 98% IACS conductivity, and consistent performance.

Many manufacturers struggle with fragmented approaches: using generic 3D printers unsuited for copper’s reflectivity, or skipping critical post-processing steps—resulting in parts that fail under thermal or mechanical stress.

XiaoJiao’s end-to-end expertise in copper-specific methods, equipment, and processes eliminates these risks, turning premium copper powder into industrial-grade components.

Key Methods in Copper Powder Additive Manufacturing

Not all additive manufacturing methods work equally well for copper. The choice depends on part complexity, material requirements, and performance goals:

1.Selective Laser Melting (SLM)

●How it works: A high-power laser selectively melts copper powder layer by layer (20-50μm layers), fusing particles into a solid structure.

●Advantages: Achieves 99.96%+ density, ideal for complex geometries (e.g., micro-channels, lattices) and high-conductivity parts (EV coolers, RF coils).

●XiaoJiao’s focus: We use SLM for 90% of copper projects—its precision matches copper’s need for uniform sintering to retain conductivity.

2.Binder Jetting

●How it works: A liquid binder bonds copper powder layers, which are later sintered in a furnace to densify the part.

●Advantages: Faster for large batches (e.g., 1000+ simple nozzles) and lower cost for non-critical components.

●Limitations: Lower density (95-97%) and conductivity (85-90% IACS) make it unsuitable for high-performance applications.

3.Direct Metal Laser Sintering (DMLS)

●How it works: Similar to SLM but sinters (rather than fully melts) powder, using lower laser energy.

●Best for: Copper alloys (e.g., CuCrZr) requiring moderate strength but not maximum conductivity (e.g., welding electrodes).

Specialized Equipment for Copper Powder Additive Manufacturing

Copper’s unique properties demand equipment engineered for its challenges:

●Laser Systems: Green lasers (515-560nm) are non-negotiable—their 40-60% absorption in copper outperforms IR lasers (5-10% absorption), preventing uneven melting. XiaoJiao uses 12 industrial-grade SLM machines with 500W green lasers, calibrated for copper’s thermal conductivity.

●Powder Handling: Closed-loop powder recyclers with inert gas (argon) protection prevent oxidation (critical for maintaining <0.008% oxygen content). Our system recovers 95% of unused powder without quality loss.

●Environmental Controls: Temperature (20-22℃) and humidity (<30%) stabilization in printing chambers—fluctuations can cause copper powder to agglomerate, ruining layer uniformity.

Step-by-Step Process: From Powder to Part

XiaoJiao’s copper powder additive manufacturing process combines rigor and efficiency, ensuring consistent results from prototype to production:

1.Design for Additive Manufacturing (DfAM)

Our engineers optimize CAD models to:

●Reduce support structures by 40% (minimizing post-processing).

●Add fillets in high-stress areas (e.g., nozzle tips).

●Integrate cooling channels aligned with powder flow characteristics.