General Questions
What services does Copper3DPrint offer?
We provide industrial copper 3D printing via LPBF/DMLS in CuCrZr, GRCop-42, and OFHC/ETP—optimized for high thermal/electrical conductivity, conformal channels, heat-exchanger cores, RF/microwave components, and tooling inserts. We also handle depowdering, bead/media finishing, precision machining, sealing/brazing, HIP/stress-relief, and metrology. From rapid prototypes to production parts, we deliver documented, repeatable quality.
Do you work with clients outside the U.S.?
Yes. We serve customers worldwide and align with common U.S./EU engineering standards and documentation practices (drawings with GD&T; FAIR-style inspection on request).
Materials & Technical
What copper alloys do you offer?
CuCrZr (good strength-to-conductivity balance), GRCop-42 (Cu-Cr-Nb, for high-temperature aerospace/combustion environments), and OFHC/ETP (maximum conductivity use-cases). We’ll recommend an alloy based on conductivity targets, temperature, pressure, vacuum/RF needs, and mechanical strength.
How accurate are your printed parts?
Typical LPBF/DMLS accuracy is ±0.10–0.20 mm or ±0.2% (whichever is greater), geometry- and size-dependent after stress-relief. For critical fits or precision bores, we add machining/reaming to achieve tighter tolerances.
What surface finish can I expect?
As-built metal surfaces are commonly Ra ~8–20 μm. We offer bead/media blasting for uniform appearance, electropolishing/chemical polishing where applicable, and precision machining to achieve ~1.6–3.2 μm Ra (or finer on critical faces) and gasket-ready sealing surfaces.
Do you provide threaded features and post-machining?
Yes. We CNC-drill/ream/tap threads and precision holes, face sealing lands, and machine datums/critical features to print-plus-machine specifications for repeatability and leak-tight performance.
What are the maximum build size and minimum feature recommendations?
- Build volume (machine-dependent): up to ~280 × 280 × 365 mm per part.
- Minimum wall: ≥0.6–1.0 mm (use 1.5+ mm for loaded features or large spans).
- Internal channels: recommend ≥1.2–1.5 mm Ø for reliable depowdering; add clean-out/escape holes for complex networks.
- Holes (as-built): ≥0.8–1.0 mm; precision holes should be reamed/drilled post-print.
- Threads: print pilot and tap/machine for best strength and tolerance.
Can you inspect and certify parts?
Yes. On request we provide CMM/3D scan reports, alloy material certificates, pressure/helium leak tests, and process traceability aligned to your quality plan.
Post-Processing & Quality
What post-processing options are available?
Depowdering, stress-relief/HIP, bead/media blast, precision machining, sealing/brazing preparation, electropolishing/chemical polishing (geometry-dependent), logo/deboss cleanup, and dimensional/flow/leak inspection. For heat-exchangers and RF parts, we propose a route balancing conductivity, surface integrity, pressure drop, cost, and lead time.
Do you help with DfAM (design for additive manufacturing)?
Absolutely. We review CAD/drawings, recommend orientation/support strategy, conformal-channel sizing, ribbing and boss design, powder-escape planning, corner radii, and call out features that should be machined post-print to hit tight tolerances and sealing specs.
Orders & Logistics
What file formats do you accept?
STEP (.step/.stp), Parasolid (.x_t/.x_b), and native CAD on request; STL/3MF meshes for quick quotes. Please include drawings for tolerances, sealing faces, threads, surface specs, pressure/leak requirements, and inspection notes.
What are typical lead times?
Rapid copper prototypes: ~5–10 business days depending on queue and post-processing. Production lots with machining/HIP/sealing/inspection: ~1–3 weeks. Urgent programs can be scheduled—tell us your target dates.
What’s the minimum order quantity?
No strict MOQ—single prototypes to full production batches are welcome. Per-part pricing improves with batch consolidation, shared finishing/inspection, and stable revision control.
Design Guidelines
Any quick tips to improve outcomes?
- Call out critical-to-function dimensions/faces (especially sealing lands and datum features).
- Size internal channels ≥1.2–1.5 mm Ø and add escape/clean-out holes for powder removal; avoid long blind pockets.
- Use consistent wall thickness and generous fillets to reduce stress concentrations.
- Plan machining allowances on precision bores, threads, and gasket faces.
- Keep overhangs within reasonable limits or allow sacrificial stock for post-machining.
- For RF and thermal parts, specify surface roughness targets on critical faces and pressure/leak requirements early.
Security & Compliance
Can you handle sensitive projects?
Yes. We follow strict data handling and can sign NDAs. If you have specific compliance or documentation needs (e.g., leak/pressure test plans, FAIR-style reports, material certs), let us know and we’ll align our workflow accordingly.