Unlock Perfect: Solve Edge Curls in Metal 3D Printing
3D printing, especially metal, transforms complex designs into reality – such as Curly edges (or warping) may damage the quality of the part. This defect occurs when corners or edges lift the build board during printing, which can lead to inaccurate dimensions, layer spacing and even printing failures. At Greatlight, we have mastered this issue through advanced technical and material expertise. This is how we solve it, and how we can solve it.
Why edge curls occur in metal 3D printing
Edge curly hair words Thermal stress:
- Quick cooling: The metal layer cures rapidly, creating internal tension between the hot new layer and the cooler layer.
- Material shrinkage: As the metal cools, it shrinks unevenly, pulling upwards the edges. High-debris alloys (such as titanium, aluminum) are particularly vulnerable.
- Adhesion failed: A poor layer of bonding, when the stress reaches the peak, the corners will fall off.
- Design defects: Large flat surfaces, sharp corners or asymmetric geometry will amplify stress concentration.
Greglight’s proven edge curling solution
1. Optimized bed adhesion and temperature control
- Mastery in building plates: We use heated build plates (maximum 400°C) and specialized coatings to ensure a flawless layer of adhesion.
- Surface preparation: Sandstone slabs and the application of adhesion promoter eliminates debris-induced detachment.
- Controlled environment: Our printers maintain uniform chamber temperature (±5°C), minimizing thermal gradients.
2. Intelligent printing parameter adjustment
- Reduce printing speed: Reduce the speed of the first 5-10 layers to cure evenly.
- Layer height: Thin layers (20–30 µm) produce less stress than thick deposits.
- Preheat: Preheat the powder bed to 80-90% of the delayed cooling gradient of the material melting point.
3. Design to reduce stress
- Raft/Edge: Add temporary sacrificial base anchoring edges and distribute pressure.
- Fish fillets and needle cut: The circular sharp corner reduces local tension.
- direction: Position the part at an angle of 15–45° to prevent large planes parallel to the plate.
4. Materials Science Innovation
- Low charge alloy: We recommend nickel alloys (Inconel 718) or tool steel for critical applications.
- Pressure-relieving powder: Custom alloys with additives such as silicon carbide minimize shrinkage.
5. Post-processing expertise
- In-situ pressure relief: Intermittent annealing during printing can offset the accumulated stress.
- Post-construction heat treatment: Our furnace evenly adjusts the part to readjust the microstructure.
- Mixed processing: We use 3D printing with CNC milling to correct the distortion with ±0.05mm accuracy.
Why collaborate with Greatlight?
- Cutting-edge technology: Industrial grade SLM/DMLS printer with AI monitoring for real-time correction.
- End-to-end control: From custom alloy formulations to heat treatment, we manage each variable.
- Speed and scale: Rush orders were reversed within 72 hours – quality no compromise.
- There is no easy way out: We deal with the root cause of warping, not through technology, but through Material innovation and physics-driven design.
in conclusion
Edge Curlling is not an inevitable flaw, it is a physical problem that can be solved. By controlling thermodynamics, refining design and utilizing materials science, Greatlight provides warpless metal parts that meet aerospace, medical and automotive standards. We are not just printers; we are solving problems to amplify your innovation.
Ready to print perfectly? Customize your project
FAQ
Q1: Can I fix the edge curls after printing?
Yes! Greatlight handles it through post-processing:
- Heat treatment to relieve stress.
- CNC machining to remove the twisted parts.
- Used for hips (thermal isometric pressure) of porous or complex parts.
Q2: Which metal is the least easy to curl?
- Inconel 718: High thermal stability.
- Stainless steel 316L: Low contraction.
- Tool Steel (H13): Excellent layer adhesion.
Q3: How does Greatlight tackle be used for large flat parts?
We combine:
- Inverse bending printing direction (diagonal inclination).
- Spacious edge + intermediate stress – utilization cycle.
- Heat the activity room during printing.
Q4: Is powder bed fusion worse with other methods of curls?
Powder bed process (SLM/DML) is most susceptible to due to rapid melting/cooling. Adhesive spraying or extrusion-based methods have less impact but have lower metal density.
Question 5: Will some thickness affect the risk of curls?
Thin wall (<1mm）凉爽的速度更快，减少卷发。厚部分（> 10mm) Requires slower printing and preheating to prevent pressure buildup.
Question 6: How does Greatlight ensure the accuracy of the dimensions if curls occur?
Our hybrid method uses a guided CNC finish. The parts are laser scanned and processed to restore tolerances within 20 microns.
Question 7: Does your solution E2E optimize the cost?
Absolutely. By preventing defects, we cut the reprint rate. For customers, this means Reduce costs + Faster turnover speed.
Lift the design with warp-free metal parts. Get quotes from today’s Greatlight – Accurately in line with innovation. 🚀
