If you’re using 3D printing for aluminum alloy parts—whether for aerospace components, industrial fixtures, or custom accessories—understanding the cost per gram is critical for budgeting. Unlike resin or PLA 3D printing, 3D printed aluminum alloys balance strength and lightweight properties but come with higher costs, ranging from 70 RMB/gram for mass-produced parts to 450 RMB/gram for small-batch, high-precision components. This guide breaks down core cost drivers, provides practical price references, shares cost-saving tips, and answers common questions to help you make informed decisions.
1. 4 Core Factors That Impact the Cost of 3D Printed Aluminum Alloys Per Gram
The cost per gram of 3D printed aluminum alloys is shaped by tangible factors—from the printing technology used to post-processing complexity. Below is a detailed breakdown with real numbers to illustrate their impact:
(1) 3D Printing Technology Type
Technology is the primary cost driver, as different methods vary in precision, speed, and equipment investment. The three most common technologies for aluminum alloy 3D printing are:
| Technology Type | Cost Per Gram (RMB/gram) | Key Characteristics | Typical Applications |
| Selective Laser Melting (SLM) | 150 ~ 450 | Ultra-high precision (tolerance ±0.02mm), ideal for complex, small-batch parts; high equipment and material costs | Aerospace components (e.g., engine brackets), medical implants |
| Electron Beam Fusion (EBM) | 80 ~ 250 | Suitable for large-scale industrial parts; lower cost than SLM but slightly reduced precision (tolerance ±0.05mm) | Industrial fixtures (e.g., drone mounts), automotive structural parts |
| Binding Jetting | 70 ~ 230 | Lowest unit cost for mass production; requires post-processing (debinding, sintering) but efficient for bulk orders | Mass-produced small parts (e.g., custom fasteners, decorative accessories) |
Example: A 30g aluminum alloy part printed via SLM costs 4,500 ~ 13,500 RMB. The same part printed via Binding Jetting costs 2,100 ~ 6,900 RMB—50% cheaper—though it needs additional post-processing steps.
(2) Aluminum Alloy Grade
The grade of aluminum alloy directly affects material costs, as specialized grades (e.g., aerospace-grade, high-strength) require refined raw materials and production processes:
| Aluminum Alloy Grade | Cost Per Gram (Material Only, RMB/gram) | Key Properties | Typical Applications |
| Al6061 (Industrial Grade) | 20 ~ 80 | Good machinability, moderate strength; cost-effective | Industrial brackets, non-critical structural parts |
| AlSi10Mg (Aerospace Grade) | 50 ~ 150 | High strength-to-weight ratio, heat-resistant; meets aerospace standards | Aircraft components, high-performance drone parts |
Key Note: Imported aluminum alloy powders (e.g., from EOS, Adaro) cost 2 ~ 3x more than domestic powders (e.g., from Chinese suppliers). For example, imported AlSi10Mg powder costs 100 ~ 150 RMB/gram, while domestic AlSi10Mg powder costs 50 ~ 80 RMB/gram.
(3) Post-Processing Requirements
Nearly all 3D printed aluminum alloy parts need post-processing to meet strength, accuracy, and appearance standards. Each step adds significantly to the total cost per gram:
| Post-Processing Step | Cost Per Gram (RMB/gram) | Purpose |
| Basic Polishing/Sanding | 10 ~ 50 | Remove surface roughness (Ra from 3.2μm to 1.6μm); eliminate layer lines |
| High-Precision CNC Trimming | 50 ~ 200 | Achieve tight tolerances (±0.01mm); refine critical features (e.g., threaded holes, mating surfaces) |
| Electroplating/Coating | 30 ~ 150 | Enhance corrosion resistance (e.g., anodizing) or add aesthetic finish (e.g., matte silver) |
| Heat Treatment | 20 ~ 80 | Improve strength (e.g., T6 heat treatment for Al6061); reduce internal stress |
Example: A 50g part needing basic sanding costs 500 ~ 2,500 RMB in post-processing. The same part needing CNC trimming + anodizing costs 4,000 ~ 11,500 RMB—8x more.
(4) Order Volume
Order volume drastically impacts cost, as fixed costs (equipment setup, programming) are spread across more parts. Small batches are far more expensive than large-scale production:
| Order Volume | Cost Per Gram (Total, RMB/gram) | Discount vs. Single Piece | Example: 50g AlSi10Mg Part (SLM Technology) |
| Single Piece/Small Batch (<10 pieces) | 250 ~ 450 | 0% (No Discount) | 50g × 350 RMB/gram = 17,500 RMB |
| Medium Batch (10 ~ 100 pieces) | 150 ~ 250 | 20 ~ 40% | 50g × 200 RMB/gram = 10,000 RMB |
| Large Batch (>100 pieces) | 70 ~ 150 | 40 ~ 70% | 50g × 100 RMB/gram = 5,000 RMB |
Example: A single 50g aerospace bracket (SLM, AlSi10Mg) costs 17,500 RMB. Ordering 100 of the same brackets drops the cost to 5,000 RMB each—71% cheaper.
2. Typical Cost Per Gram: Scenario-Based Breakdown
To see how all these factors align, below are three common scenarios for 3D printed aluminum alloy parts:
| Scenario | Technology | Aluminum Alloy Grade | Post-Processing | Cost Per Gram (RMB/gram) | Example (10g Part Total Cost) |
| Small-Batch High-Precision Part | SLM | AlSi10Mg | CNC Trimming + Heat Treatment | 250 ~ 450 | 2,500 ~ 4,500 RMB |
| Medium-Batch Industrial Part | EBM | Al6061 | Basic Polishing + Anodizing | 100 ~ 200 | 1,000 ~ 2,000 RMB |
| Large-Batch Mass-Produced Part | Binding Jetting | Al6061 | Sanding + Deburring | 70 ~ 150 | 700 ~ 1,500 RMB |
3. Practical Cost Reference for Common 3D Printed Aluminum Alloy Parts
To quickly gauge reasonable prices, below is a table of common part types and their typical costs:
| Part Type | Size/Weight | Technology | Cost Per Gram (RMB/gram) | Total Part Cost (RMB) |
| Custom Decorative Keychain | 2cm / 10g | Binding Jetting | 70 ~ 120 | 700 ~ 1,200 |
| Industrial Drone Mount | 10cm / 50g | EBM | 100 ~ 180 | 5,000 ~ 9,000 |
| Aerospace Engine Bracket | 8cm / 40g | SLM | 250 ~ 400 | 10,000 ~ 16,000 |
| Mass-Produced Fasteners | 1cm / 5g | Binding Jetting | 70 ~ 100 | 350 ~ 500 |
4. 4 Practical Tips to Reduce the Cost of 3D Printed Aluminum Alloys Per Gram
While 3D printed aluminum alloys are more costly than basic plastics, these strategies can lower expenses without sacrificing quality:
(1) Optimize Part Design to Cut Material Use
- Simplify geometry: Remove redundant features (e.g., unnecessary curves, oversize walls) to reduce part weight by 15 ~ 30%. For example, a 50g bracket optimized to 35g saves 15g of material—cutting costs by 30%.
- Use hollow structures: For non-load-bearing parts (e.g., decorative keychains), design thin-walled (≥1mm) hollow interiors to reduce material consumption by 20 ~ 40%.
(2) Choose Domestic Aluminum Alloy Powders
Domestic powders (e.g., from Chinese manufacturers) are 50 ~ 60% cheaper than imported alternatives and meet most industrial standards. For example, using domestic AlSi10Mg powder (50 ~ 80 RMB/gram) instead of imported (100 ~ 150 RMB/gram) cuts material costs by half.
(3) Batch Orders to Unlock Discounts
Even small increases in order volume yield significant savings. If you need 50 parts over 6 months, order all 50 at once instead of 10 per month—this unlocks a 20 ~ 40% discount, reducing the cost per gram by 20 ~ 30%.
(4) Simplify Post-Processing When Possible
- Skip unnecessary steps: For non-precision parts (e.g., decorative keychains), avoid CNC trimming and use basic sanding instead—saving 50 ~ 200 RMB/gram.
- Combine post-processing: Handle heat treatment and anodizing at the same facility to avoid shipping costs, reducing overall fees by 10 ~ 15%.
Yigu Technology’s Perspective on 3D Printed Aluminum Alloy Costs
At Yigu Technology, we believe matching technology and alloy grade to project needs is key to cost-effective 3D printed aluminum alloys. Many clients overspend by using SLM for mass-produced parts or imported powders for non-critical components—for example, using SLM (300 RMB/gram) for a simple bracket that works with Binding Jetting (100 RMB/gram). Our team recommends SLM with domestic AlSi10Mg for small-batch aerospace parts and Binding Jetting with Al6061 for mass-produced industrial components. We also optimize designs to reduce material use by 15 ~ 30% and negotiate bulk powder discounts. Our goal is to deliver high-quality 3D printed aluminum alloy parts at the lowest possible cost per gram.
FAQ
- Why is 3D printed aluminum alloy more expensive than 3D printed plastic?
3D printed aluminum alloy requires high-cost equipment (SLM/EBM machines cost 1 ~ 10 million RMB vs. 10 ~ 30,000 RMB for resin printers) and specialized metal powders (20 ~ 150 RMB/gram vs. 0.02 ~ 0.2 RMB/gram for resin). Post-processing (e.g., CNC trimming, heat treatment) is also more complex and costly for metal parts.
- Can I use 3D printed aluminum alloy for small decorative parts (e.g., keychains) without overspending?
Yes—use Binding Jetting with Al6061 powder and basic sanding (no electroplating). A 10g keychain made this way costs 700 ~ 1,200 RMB, affordable for small-batch custom orders. Avoid SLM or high-grade AlSi10Mg for decorative parts, as they double or triple costs.
- How much does post-processing add to the total cost per gram of 3D printed aluminum alloy?
Post-processing typically adds 10 ~ 350 RMB/gram, depending on steps. Basic sanding adds 10 ~ 50 RMB/gram, while CNC trimming + anodizing adds 80 ~ 350 RMB/gram. For most industrial parts, post-processing accounts for 20 ~ 50% of total cost per gram.