Many manufacturers exploring additive manufacturing turn to metal 3D printing with high hopes. Whether it’s investing in a 3D printer that prints metal, outsourcing to a metal 3D printing service, or hunting for the latest aluminum 3D printer, there’s a common assumption: if it’s strong and functional, it must be made of metal.
But in practice, metal printing isn’t always the best path forward. Between high costs, long lead times, and complex post-processing, companies are starting to realize that metal 3D printing often overpromises and underdelivers—especially when alternatives can deliver similar performance with less effort and cost.
Let’s look at how forward-thinking manufacturers are turning to carbon-fiber-reinforced thermoplastics and high-temperature polymers to achieve the same results, often with better outcomes.
The Problem with Metal 3D Printing
While the idea of printing in aluminum or stainless steel sounds impressive, the reality is often expensive and slow. A metal 3D printer or aluminum 3D printer can cost hundreds of thousands of dollars, require complex safety protocols, and involve extensive post-processing like machining or heat treatment.
And for companies that opt for a metal 3D printing service, the turnaround time can still be long—and that’s before design changes or tooling adjustments come into play. More often than not, the project is overengineered, simply because metal seemed like the only way to get durability.
Cases Where Companies Successfully Replaced Metal Parts Without Metal 3D Printing
Boom Supersonic
“We reduced our lead time from 7 weeks to 14 hours and saved 98% on material cost.”
Boom Supersonic replaced traditionally machined aluminum bleed air ducts with 3D printed parts made from ULTEM™ 1010 resin, a high-temperature thermoplastic. This switch eliminated the need for costly and time-consuming CNC machining. By using FDM additive manufacturing, Boom reduced lead time from 7 weeks to just 14 hours and cut material costs by 98%, all while gaining greater design flexibility for optimal performance during engine testing.
Graco Metal Forming Die
“We printed a Nylon-CF10 die that formed carbon steel brackets—and it held up perfectly.”
Graco Inc. replaced traditional machined metal forming dies with 3D printed tools made from FDM Nylon-CF10, a carbon-fiber-reinforced thermoplastic. The printed dies were used to successfully form 14-gauge carbon steel brackets under 0.8 tons of pressure—without deformation or wear after 40 cycles. This switch eliminated a month-long lead time, delivering tools in just 3 days and cutting costs by 80%, demonstrating that metal-forming performance can be achieved without metal printing or CNC machining.
Due Pi Greco (Italy)
“Our carbon-fiber 3D prints replaced CNC-machined aluminum—faster, cheaper, and just as strong.”
Italian design firm Due Pi Greco replaced CNC-machined metal parts with FDM Nylon 12CF, a carbon-fiber-reinforced thermoplastic, using Stratasys Fortus 3D printers. The switch allowed them to produce high-performance components—such as a Formula SAE race car airbox—with the strength and reliability of metal, but at a fraction of the cost and time. This transformation not only improved turnaround and part quality but also opened new business opportunities, proving that metal-like performance is possible without metal printing.
Santa Cruz Bicycles
“3D printed ULTEM™ tools helped us produce custom carbon frames in weeks—not months.”
Santa Cruz Bicycles replaced traditional aluminum tooling with 3D printed mandrels made from ULTEM™ 1010 resin to manufacture a custom carbon-fiber bike frame. Instead of investing time and money into machining metal molds, the team used FDM printing to create precise, heat-resistant tools in-house—enabling them to go from CAD to a ridable prototype in just weeks. This approach also unlocked faster design iteration, reduced costs, and expanded 3D printing use across their R&D and test labs without relying on metal printing or CNC machining.
Material Alternatives That Compete with Metal
Here’s how these materials are outperforming expectations—even where metal was once the default:
| Material | Comparable to | Why It Works |
|---|---|---|
| FDM Nylon-CF10 | Aluminum, mild steel | Strong, stiff, wear-resistant, ideal for tools, fixtures, and dies |
| ULTEM™ 1010 Resin | Stainless steel, high-temp alloys | High heat resistance, chemical durability, aerospace- and medical-grade |
| FDM Nylon 12CF | Machined aluminum | Excellent surface finish and mechanical performance, ideal for auto/aero |
These aren’t just theoretical equivalents—they’re field-proven alternatives used in environments where strength, durability, and heat resistance matter.
Why This Matters
Customers may come asking for metal printing, assuming only metal 3D printing can give them strong, reliable parts. But smart engineers know it’s not about the material—it’s about the performance. High-performance 3D printing materials like Nylon-CF10, ULTEM™ 1010, and Nylon 12CF deliver equivalent—or even superior—results in many industrial applications. And they do so faster, at lower cost, and with more design freedom than a metal 3D printing service can offer.
If you’re considering metal 3D printing or investing in an aluminum 3D printer, ask yourself: Do you truly need metal? In many cases, the answer is no—and your project, timeline, and budget will be better off for it. With today’s advanced polymers and composite materials, the smartest choice may not be the heaviest one.
