METAL X DESIGN GUIDE

Metal X Design Reference Sheet

Listed dimensions are as designed for your final part unless otherwise specified. These guides serve as recommendations and
may not reflect all implementations, since 3D printing is a geometry dependent process.

Maximum Part Size with Sinter-1

X: 235.0 mm (9.25”)
Y: 68.3 mm (2.69”)
Z­1: 65.5 mm (2.58”)
Z2: 80.0 mm (3.19”)
R Z2 R: 55.5 mm (2.18”)
Z1
These are the maximum post-sintered dimensions of a part made with the Metal
X
Y
X system using the Sinter-1. This includes scaling factors, the part raft, and the
setter tray. Software limits parts to a bounding box of X, Y, Z1. Due to the shape of
the Sinter-1 tube, taller parts can extend up to Z2 in height if their top surface fits
within a radius of R centered along the part.

Minimum Part Dimensions

X: 2.0 mm (0.079”)
Z
Y: 2.0 mm (0.079”)
Z: 1.3 mm (0.049”)
X Y
Minimum part size is limited to the extrusion width and height of each bead. The
dimensions are derived from the minimum number of roof layers, floor layers, and
shells needed to print a part successfully.

Maximum Unsupported Overhang

θ: 45o

This is the minimum angle to the horizontal at which a feature of a part can
θ print without needing supports to hold it up. Eiger will generate supports for all
overhangs with angles below 45 o .

Z Minimum Hole Diameter

XY: 1.5 mm (0.059”)

Z: 1.0 mm (0.039”)

Holes with too small a diameter may close off during printing or print inaccurately.
XY Horizontal surface holes (Z) print more precisely than vertical surface holes (XY).

Z Minimum Post Diameter

XY: 3.0 mm (0.118”)

Z: 3.0 mm (0.118”)

Posts with too small a diameter may not print or sinter precisely. Consider adding
fillets to the bases of posts to reduce the potential for shearing in the green state.
XY

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METAL X DESIGN GUIDE

Metal X Design Reference Sheet

Minimum Engraved Features

Z Layer features
H: 0.13 mm (0.005”)
H
W: 0.50 mm (0.019”)
W

Horizontal XY features
H: 1.5 mm (0.059”)
H
D

D: 0.5 mm (0.019”)

Vertical XY features
D
W

W: 0.5 mm (0.019”)
D: 0.5 mm (0.019”)

An engraved feature is one that is recessed below the surface of the model.
Common examples include lettering and texture. Engraved features may blend
into the rest of the model if they are too small.

Minimum Embossed Features

Z Layer features
W
H: 0.13 mm (0.005”)
H
W: 1.0 mm (0.059”)
D
Horizontal XY features
H H: 1.3 mm (0.049”)
D: 0.5 mm (0.019”)

D
W Vertical XY features
W: 1.0 mm (0.059”)
D: 0.5 mm (0.019”)

An embossed feature is one that is raised above the surface of the model.
Common examples include lettering and texture. Embossed features may
blend into the rest of the model if they are too small.

1.0 mm Important note: To prevent gaps in features less than

(0.039”)
than 2.0 mm (0.079”) wide, design embosses to be even
multiples of 0.25 mm (0.01”), the width of a single post-
sintered extrusion of metal.

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METAL X DESIGN GUIDE

Optimize For Printing

As you design your part, consider how it can be optimized for the
printing process. Below are four considerations to keep in mind
when designing: 57.5

x2
Ø2

6
7.5

6.
Ø
1. Identify Critical Dimensions

17.5
3D printers have higher precision in planes parallel to the build
plate. What are your critical dimensions or features?
R6
8
Units: mm

2. Maximize Bed Contact

Greater surface area on the print bed minimizes supports and

improves bed adhesion. Which face of your part contacts the
bed?

3. Reduce Supports

Fewer supports reduce printing and processing time. How can

you design to minimize supports? Are the supports in your part
accessible?

4. Consider Batch Processing

The more parts you can pack into a sintering run, the lower batch
cost you have per part. How will your part pack among others in
the furnace?

Modify Overhangs to Optimize Supports

Supports are necessary to prevent overhang collapse during printing and sintering. Consider where your parts will require
supports and what you can do to minimize supports to decrease print time. Ensure the supports on your part are easy to
access and remove before you print. If not, consider modifying overhangs to improve support removal.

Eliminate Supports Simplify Support Removal

Chamfer small overhangs at 45° Break up supports with 45° chamfers on edges

Teardrop XY holes to clear channels Add slits to separate segments

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METAL X DESIGN GUIDE

Optimize For Washing

Shell Out Thick Parts

The thicker your part is, the longer it will take to wash. Shell out
large volumes and increase surface area to minimize the time your
parts spend in the wash. Try to maintain consistent wall thickness
across your part.

Thicker part sections Shell parts for a faster

increase wash time wash time

Wash Bowls Upside Down

Wash bowl-shaped parts upside down (no need to change print
orientation) because the washing solvent is lighter than the binder
material. When upside-down, the solvent permeates up into the
bowl, resulting in a faster wash time.

Slower wash time in printed Faster wash time when

orientation inverted

Optimize For Sintering

Reduce Stress Concentrations

Parts undergo thermal stresses when sintering because they
are pulling themselves together as they shrink. Reduce stress
concentrations by filleting your edges and designing gradual
instead of sharp changes in thickness.

Sharp edges may cause Smooth transitions reduce

deformation during sintering deformation

Ensure Features are Well Balanced

As parts go through the sintering process, the heat induces a
clay-like state that makes them malleable. If your parts don’t
need supports, ensure they are inherently stable in their printed
orientation. Avoid top-heavy, cantilevered, or tall and thin
features.
Cantilevered features may Balanced features stay
topple when sintered supported during sintering

Chamfer Bottom Edges

The bottom edge of your part may splay out during sintering.
Adding a 0.5-1.0 mm (0.02”-0.04”) chamfer to the bottom edges of
your part will prevent splayed edges, especially on small features
like holes and channels.
Straight bottom edges can Splaying avoided with
splay out during sintering chamfered bottom edge

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METAL X DESIGN GUIDE

Strategic Metal Printing Practices

Think critically about what aspects of your design need to be 3D printed. Some features could be implemented more efficiently
with other manufacturing methods. When appropriate, integrate other parts into your design to save on print time, design
complexity, and cost. Below are some examples:

Use Pins for Alignment Features

Improve alignment precision and save material and print time by
pressing dowel pins into your parts or using shoulder bolts for
location. Dowel pins pressed into this gripper jaw locate it on a
robotic arm. This design change reduces supports and simplifies
print orientation.

Separate Printed from Simple Features

Isolate complex part features for metal 3D printing. Printing
an impeller with an integrated shaft will sacrifice optimal print
orientation for furnace orientation — it can only fit in the Sinter-1
sideways. Instead, the impeller can be printed apart from a turned
shaft to decrease print time and part complexity. The retaining
rings locate the impeller on the shaft, and the key acts as a shear
point that can be swapped if it fails.

Isolate Properties with Modular Features

This sheet metal stamp consists of a blank with metal printed
inserts. Isolating the metal inserts as separate parts localizes
metal properties to only the region they are required, so you don’t
need to print an entirely new tool for every revision. This also
makes maintenance and tool repair easy.

DON’T PRINT YOUR HARDWARE

Printing hardware is a poor use of the Metal X technology — purchasing off-the-shelf hardware is almost always more cost-
and time-efficient and produces better results. Hardware like bushings, bearings, and springs are produced with specialized
manufacturing processes and will not behave the same way when printed. Washers, nuts, bolts, and similar hardware are
cheaper and more effective to purchase than to print.

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METAL X DESIGN GUIDE

Post-Processing Metal Parts

Green State Sanding
Wet sanding green parts under warm water with 240-320 grit sandpaper or
Scotch-Brite leaves a matte finish once sintered. Green parts are fragile, so be
cautious as any modifications may affect precision or sintering performance.
Sand over a receptacle or filter to prevent sink clogging, and use proper PPE. Z Removal
0.1-0.3mm
(0.004”-0.012”)

Machining and Polishing Sintered Parts XY Removal

0.2-0.5 mm
(0.008”-0.019”)
The diagram on the right serves as a recommendation for post-processing
parts to remove layer-line deviations without running the risk of exposing
infill. Offset faces you wish to machine in your design so that when material is
removed you can meet your tolerances.

0.5 mm
(0.019”) Important note: Printed metal parts have a wall thickness of 1.0 mm (0.039”) and a roof and floor
thickness of 0.5 mm (0.019”). When post-processing parts, don’t remove more than this much or you will
1.0 mm
(0.039”) cut through the shells entirely and expose infill.

Threads
Tapped Threads Printed Threads

Tapped threads will be tighter tolerance than printed Printed threads may need to be chased with a tap or need
threads. Use 50% thread engagement for your tapped hole lapping compound for an even thread.
size in steels and other hard metals.

Vertical Threads
Tap vertical threads less Print or tap threads between M3 Print vertical threads larger
than M3 (or #5-40) (or #5-40) and M10 (or 3/8”-16) than M10 (or 3/8”-16)

Angled and Horizontal Threads

Tap angled and Print angled and

horizontal threads less horizontal threads larger
than M8 (or 5/16”-18) than M8 (or 5/16”-18)

Some metal printed parts may be difficult to fixture for machining or tapping due to their complex geometry. You can use
Markforged composite printers to create conformal workholding to hold the metal parts in these cases.

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METAL X DESIGN GUIDE

Metal Selection and Treatment

Below we list the main properties and applications of each metal we have available for the Metal X system, along with a
summary of heat treatment for each material. Heat treating primarily alters the ductility, toughness, hardness, and strength
of a metal part. Those treated at higher temperatures typically have lower strength and hardness, but higher ductility and
toughness. While specific properties may vary depending on part size and complexity, parts in the annealed condition have the
highest ductility and are easiest to work with. For more specific details, reference our data sheet or other heat treating guides.

17-4 PH Stainless Steel

17-4 PH Stainless Steel is a common martensitic stainless steel characterized by high strength and excellent corrosion
resistance. The material can be precipitation hardened to adjust mechanical properties to fit your application. This easy-to-
weld, versatile steel is widely used in the metalworking, aerospace, petrochemical, and medical industries.
Heat To Time at Yield Strength Elongation Hardness
Heat Treatment Information Condition °F (°C) Temp. MPa % in 2” Rc

A 1950 (1066) 30 min 760 5 34

Post-sintered 17-4 PH Stainless Steel is in a near-
annealed state that can be easily worked with. H900 900 (482) 1 hr 1170 10 40

Annealing to Condition A is only necessary if a part H925 925 (496) 4 hrs 1070 10 38
needs re-treatment. H1025 1025 (551) 4 hrs 1000 12 35

Heat Treatment: Heat the part to the temperature H1075 1075 (580) 4 hrs 860 13 32
and for the time span listed in the table to the right H1100 1100 (593) 4 hrs 795 14 31
based on the desired condition. Post-sintered 17-4
H1150 1150 (621) 4 hrs 725 16 28
does not need annealing prior to treatment. All parts
should be air cooled. H1150-M 1400 (760) 2 hrs 520 18 24
followed by followed by

1150 (621) 4 hrs

Material data reflects typical values for wrought materials. Printed part properties may differ.

H13 Tool Steel

H13 Tool Steel is a hot-work class steel characterized by high temperature hardness and abrasion resistance. It’s tough,
impact resistant, and easy to machine and polish. H13 is resistant to thermal fatigue and premature heat-checking, and has
excellent through-hardening properties, making it a great fit for molding applications like inserts, cores, and dies.
Temper To Hardness
Heat Treatment Information °F (°C) Rc

900 (482) 54
1. Anneal: H13 is not annealed when sintered and will need to be before heat treatment
or machining. Heat the part to 1553-1652°F (845-900°C) at 400°F (222°C) per hour and 1000 (538) 52
hold at temperature for one hour per inch of maximum part thickness. Cool slowly at a 1050 (566) 50
rate not exceeding 50°F (28°C) per hour until 1000°F (538°C), then continue cooling in 1100 (593) 46
air. The hardness of annealed material should be around 90-95HRB.
1150 (621) 36
2. Preheat: Use a double preheat to minimize distortion by heating the part at 400°F 1200 (649) 30
(204°C) per hour to 1100-1250°F (593-677°C) and letting the part equalize, then heat to
As Sintered 40
1500-1600°F (816-871°C) and equalize again.
Material data reflects typical values for
3. Austentize: Heat rapidly to 1800-1890°F (982-1032°C) and hold for 30 minutes to 2 wrought materials. The following were
referenced in creating these guides:
hours. Use a salt bath or controlled atmosphere furnace to minimize decarburization.
17-4 PH Stainless Steel:
ASTM A 564/A 564M: Standard Specification
4. Quench: Quench the part in still air. Temper immediately after quenching. You may for Hot-Rolled and Cold-Finished Age-
Hardening Stainless Steel Bars and Shapes
use an interrupted oil quench to below 150°F (65°C) on large parts or to maximize Specialty Steel Supply: specialtysteelsupply.
hardness and toughness, but there is some risk of cracking during the process. com/brochure/17-4-technical-data.pdf
AK Steel: aksteel.com/sites/default/
files/2018-01/174ph201706.pdf
5. Temper: Temper at a minimum of 50°F (28°C) above the maximum operating
H13 Tool Steel:
temperature of the part, using the table to the right as a guide. Temper at one hour per ASTM A681: Standard Specification for Tool
Steels Alloy
inch of maximum part thickness for at least two hours. A second temper at 25-50°F (14-
Hudson Tool Steel: hudsontoolsteel.com/
28°C) below the first is recommended, especially when heat checking is a problem. technical-data/steelH3
Cincinnati Tool Steel Company: cintool.com/
documents/mold_quality/H13.pdf