What is the difference between wire DED and powder DED metal 3D printing?

Wire DED feeds solid metal wire into a laser melt pool; powder DED blows metal powder into it. Wire is safer to handle, produces almost no waste, and costs less per kilogram because it uses standard welding feedstock. Powder can achieve finer feature detail and handles some alloys wire cannot. For large structural parts, repairs, and near-net-shape work, wire is usually the better economic choice. Accufacture works with both — Meltio wire-laser DED and Laserline powder DED — so we can recommend by application rather than by what we happen to sell.

How much does a metal 3D printer cost?

Industrial metal DED systems generally range from the low six figures for a standalone printer to several hundred thousand dollars for a fully integrated multi-axis robotic cell with enclosure, safety systems, and tooling. The variables that move the number most are build volume, number of axes, laser power, wire configuration, and how much fixturing your parts require. We quote against your actual parts rather than a list price, because a system sized for what you make is almost always cheaper than a system sized for a brochure.

What materials can you print?

Stainless steels including 316L and 17-4 PH, carbon and tool steels, titanium including Ti-6Al-4V, Inconel 625 and 718, aluminum alloys, copper, and nickel-based alloys. Because the feedstock is standard welding wire, qualifying a new alloy is generally faster and cheaper than with powder systems. If you have a specific material requirement, ask — the answer is often yes.

Can metal 3D printed parts be used in production, or only for prototypes?

In production. Wire-laser DED produces fully dense parts — our Alchemist I cell achieves 99.998% density — with mechanical properties comparable to wrought material in most alloys. Parts come off near-net-shape and are machined to final tolerance, the same as a casting or forging would be. The technology is used in production today for tooling, repairs, and structural components in automotive, aerospace, and defense.

How accurate is metal DED, and do parts need machining afterward?

DED is a near-net-shape process. Expect surface finish and dimensional variance in the millimeter range as-printed, so any surface with a real tolerance requirement gets machined. This is normal and it is planned into the part: you print close to final geometry with generous stock on critical faces, then finish those faces. The advantage over machining from billet is that you start with far less material to remove.

Can I convert an existing FANUC robot into a metal 3D printer?

In many cases, yes — and Accufacture is the only company in North America authorized by both FANUC and MELTIO to do it. Whether your specific robot is a candidate depends on its model, payload, reach, controller generation, and condition, plus whether your facility can accommodate the laser safety requirements. Send us the robot's model and controller details and we will tell you honestly whether a retrofit makes sense or whether a purpose-built cell is the better investment.

What lead time should I expect for a printed part?

For a single part from an existing material we have on hand, typically days rather than weeks. Complex parts, new alloys, or work requiring custom fixturing take longer. Send us a STEP file and we will give you a real date rather than a range.