Additive manufacturing of metal filament: when it can replace metal injection moulding

During the last years, many manufacturing processes have been developed combining the typical flexibility of polymeric processes and the resistance of metal components. Among them, metal injection moulding (MIM) is of considerable importance, but this technique is considered very expensive in terms of energy and investments. For this reason, new solutions are being implemented. In particular, the use of a polymeric material extrusion machine to print a metal filament (i.e. a polymeric filament loaded with metal powder) can be an alternative solution characterized by low investment and a more flexible process chain with respect to the MIM ones. In this context, it is necessary to investigate the economic aspects to select the best process according to the component requirements in terms of specifications, level of customization, and production volume. The presented developed cost model and its application are, identifying the different trends of cost and productivity, underlining the weaknesses and the strengths of the two technologies, and showing the convenience of the process according to the considered production volume.