Metal Myths Exposed: The Realities of Metal Powder Bed 3D Printing
October 28, 2025 | Reading time: 9 min
If you’ve spent any time around manufacturing, you know that myths and misconceptions can stick around chewing gum under a desk. Nowhere is this more true than in the world of metal 3D printing, especially as it relates to laser powder-bed fusion (LPBF), also known as Direct Metal Laser Solidification (DMLS). To address some of these misconceptions, we partnered with Pete Zelinksi, and created the “Metal Myths Exposed” video series to shine a light on the realities of modern metal additive manufacturing and, hopefully, retire a few outdated ideas along the way.
Why Bother Busting Myths?
AM technology sometimes evolves quickly, but opinions often linger. Many manufacturers still hold a view of metal 3D printing through the lens of its early limitations – limited materials, questionable repeatability, “slow speeds,” and concerns about porosity. Some long-held perceptions may have had an element of truth, but let’s spend some time talking about metal AM, circa 2025.
1. Repeatability: Yes, You Can Count On It
The first myth we tackled is the idea that LPBF can’t deliver repeatable results. Spoiler alert: it can, and it does. The key is understanding that repeatability isn’t just about the printer, it’s about the entire process chain. From controlling the thermal history during printing to ensuring proper heat treatment and even paying attention to minute details like shipping (yes, shipping!). Every step matters and can be measured and managed. When you apply the same discipline to AM as you do to casting or forging, you’ll find LPBF is as reliable as your favorite torque wrench.
2. Speed: It’s Not a Race, It’s a Workflow Revolution
Is metal 3D printing slow? Well, if you’re just comparing build times, maybe. But that’s like judging a relay race by the first runner alone. LPBF eliminates tooling, reduces or eliminates assembly steps, and can turn a months-long procurement process into a matter of days. Plus, advances like multi-laser systems and thicker layers are making builds faster than ever. The real win? Streamlining your entire workflow, not just shaving seconds off the clock.
3. Porosity and Density: Much Ado About (Almost) Nothing
Questions about porosity of metal AM parts has haunted the reputation of metal 3D printing since EOS first commercialized its EOSINT M 250 printer. But here’s the reality: with today’s well-controlled processes, LPBF parts are nearly fully dense. In fact, we often scrutinize metal AM parts more than their cast or forged cousins. The conversation should shift from “Is there porosity?” to “Where is it, and does it matter for my application?” in most cases you'd find with DMLS parts, overall porosity is not a huge concern.
4. Measurement and Qualification: Raising the Bar and Meeting the Challenge
If you think additive manufacturing is held to a higher standard, you’re right. Qualification and measurement in LPBF are rigorous, sometimes bordering on overzealous. But that’s a good thing. By defining clear requirements and leveraging advanced process monitoring, we ensure that every part meets or exceeds expectations. And yes, sometimes we measure more than we need to, but wouldn’t you rather be safe than sorry? As more data becomes available, I assure you this will become less burdensome with time.
5. Material Selection: Welcome to the Golden Renaissance
The myth that LPBF is limited to a handful of alloys is as outdated as dial-up modem. Today, there are dozens of qualified materials available, with more being developed all the time. From aerospace-grade aluminum to marine alloys, the possibilities are expanding rapidly. Additive manufacturing isn’t just keeping up it is accelerating new material development and driving a new era of material innovation.
Wrapping Up: The Future Is Now
Let’s remember, metal AM is still relatively new and has come a long way to establishing itself as a key R&D, prototype, and production tool in just a short amount of time. But in that time, some its early perceptions and misconceptions linger. Applying skepticism is natural, but metal AM has is rising to the challenges and it is time to put away a few of the older myths. Whether you’re a seasoned engineer or just curious about what’s possible, I invite you to watch the “Metal Myths Exposed” series. You might just find that the biggest myth of all is that additive manufacturing is still “the manufacturing technology of tomorrow.” AM is already here and plays an integral role in advanced manufacturing with some of the world’s biggest brands. Stay curious, stay skeptical, and never stop questioning the status quo, after all, that’s how progress happens.
If you have questions or would like to explore how metal AM can be leveraged within your organization, feel free to reach out – our experts are available to support you. You can contact Ankit Saharan directly at ankit.saharan@eos-na.com or via LinkedIn.
