COLD METAL FUSION

High-strength, production-ready titanium 3D printing for complex parts that demand performance.

  • Production-Grade Titanium - Lightweight, corrosion-resistant, near-forged density
  • High Strength - Tensile strength over 1000 MPa with 10–15% elongation at break
  • Complex Geometries - Achieve intricate designs not possible with machining
  • No Thermal Compensation Needed - SLS-based system ensures isotropic shrink and dimensional fidelity
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High-Performance Titanium Parts, Simplified

Cold Metal Fusion (CMF) is the go-to solution when you need strong, lightweight, corrosion-resistant metal parts—without the cost, heat, or complexity of traditional metal printing. Built on a selective laser sintering (SLS) backbone, CMF combines polymer-coated titanium powder with advanced debinding and sintering to achieve near-forged performance.

At Tronix3D, we use this innovative process to help engineers and manufacturers create mission-critical components for aerospace, medical, defense, and high-performance industrial systems. Whether you’re launching a new product or replacing a legacy metal part, CMF gives you unmatched freedom to move forward fast—with strength you can count on.

How Does Cold Metal Fusion Work?

Cold Metal Fusion (CMF) combines the design flexibility of polymer powder-bed fusion with the final strength of sintered titanium. The process begins with a laser fusing layers of polymer-coated metal powder, building a “green part” that is strong enough for handling but not yet fully metallic.

From there, CMF follows a multi-step industrial-grade workflow:

  1. Powder Removal & Cleaning – Loose powder is evacuated, and parts are gently cleaned

  2. Green Part Processing – Optional milling or inspection is done while parts are still soft

  3. Solvent Debinding – Polymer binders are dissolved in a controlled chemical process

  4. Sintering – Parts are densified in a high-temperature furnace, achieving up to 99.5% titanium density

  5. Finishing – Final post-processing includes CNC machining, polishing, laser marking, or anodizing if required

This smart, scalable method delivers high-strength metal parts with excellent dimensional accuracy, ideal for aerospace, med tech, and structural applications without the challenges of DMLS or casting.

At Tronix3D, we guide you through every stage, from design for additive to precision finishing, ensuring your titanium parts meet exacting performance standards.

Photo Credit: Nexa3D

Benefits of Cold Metal Fusion vs. Other Metal Manufacturing Methods

Cold Metal Fusion (CMF) stands out for delivering high-strength, near-forged titanium parts—without the high heat, cost, or complexity of traditional metal 3D printing.

Compared to DMLS (Direct Metal Laser Sintering):

  • Lower Thermal Stress: CMF avoids melting metal powders, reducing internal stress, warping, and distortion.
  • Faster & Safer Processing: No need for ultra-high-power lasers or inert gas chambers.
  • Better Scalability: Green parts can be processed in large batches, ideal for low- to mid-volume production.

Compared to CNC Machining:

  • Less Waste: CMF builds near-net-shape parts, minimizing expensive material scrap.
  • More Design Freedom: Enables internal channels, undercuts, and lightweighting impossible with subtractive methods.
  • Lower Tooling Costs: No fixturing, no retooling—faster transitions from prototype to production.

Why Engineers Choose CMF

  • Titanium parts that rival machined or forged metal in strength and precision
  • Consistent results from prototype through low-volume production
  • Reduced post-processing and distortion compared to DMLS

Whether you’re developing aerospace hardware, surgical tools, or structural components, CMF gives you the strength of metal with the flexibility of additive without the usual headaches of powder-bed fusion.

Materials Specifications for CMF

At Tronix3D, we utilize a titanium-based powder specifically engineered for Cold Metal Fusion. This material offers exceptional mechanical properties and geometric precision—making it ideal for performance-critical applications in aerospace, robotics, and med tech.

Photo Credit: Nexa3D

Grade 5 Titanium (Ti6Al4V)

An aerospace-grade titanium alloy known for its strength-to-weight ratio, corrosion resistance, and biocompatibility.

Perfect for brackets, implants, housings, and structural hardware in demanding environments.

Material Properties (After Sintering):

  • Tensile Strength: ~1000+ MPa

  • Elongation at Break: 10–15%

  • Density: 98.5–99.5% (HIP optional)

  • Surface Finish: 8–12 Ra µm as-sintered

  • Dimensional Tolerance: ±0.2 mm typical

Why it Matters

  • High-performance titanium with aerospace-grade strength
  • Corrosion resistance for harsh or medical environments
  • Supports complex, lightweight, and consolidated part designs
  • Reliable for both prototyping and end-use production

Best Applications for Cold Metal Fusion

Cold Metal Fusion is trusted by engineers and manufacturers for titanium parts that demand mechanical strength, fine detail, and exceptional dimensional stability. It’s ideal for both validated prototypes and end-use metal components.

Top Applications Include:

  • Structural Prototypes: Validate metal form, fit, and mechanical performance in early-stage development
  • Flight-Ready or Surgical Components: Produce titanium parts that meet demanding regulatory or field performance needs
  • Mounting & Bracketing Systems: Strong, lightweight titanium hardware for aerospace, robotics, and med tech
  • Thermal & Load-Bearing Parts: Components designed to withstand mechanical stress, temperature extremes, or corrosive environments
  • Consolidated Assemblies: CMF supports internal channels, thin walls, and part consolidation to reduce complexity and weight

Whether you need 1 titanium prototype or a short run of production parts, CMF offers unmatched strength, reliability, and design freedom without the downsides of DMLS or casting.

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