Aluminium 3D Printing
3D Printing EOS Aluminium Al5X1, AlF357, AlSi10MG, Al2139 & Constellium CP1
Aluminium is one of the most versatile metals for industrial 3D printing, valued for its exceptional strength-to-weight ratio, corrosion resistance, and thermal conductivity. With advanced metal powder choices and industry-leading additive manufacturing systems, EOS provides the solutions for producing high-quality, lightweight, and complex aluminium components. Our materials, processes, and systems work seamlessly together to deliver reliable, repeatable results - from rapid prototyping to serial production. Explore our portfolio of aluminium powders to find the perfect fit for your application.
Why Choose Aluminium 3D Printing Over Traditional Manufacturing?
Traditional manufacturing methods like casting and CNC machining have long dominated aluminium part production, but they often come with constraints: expensive tooling, long lead times, and limited geometric complexity. Aluminium 3D printing removes many of those barriers.
With metal additive manufacturing, engineers can consolidate multiple components into a single part, design intricate internal channels for thermal management, and produce lightweight structures that would be impossible to machine or cast. The economics shift, too: For low-to-medium production volumes, 3D printing eliminates the need for moulds entirely, reducing upfront costs and enabling faster iteration cycles.
For high-volume production, aluminium additive manufacturing complements traditional methods by accelerating prototyping and producing complex tooling inserts - such as conformal-cooled moulds - that improve cycle times downstream.
Choose the Right Aluminium 3D Printing Option for Your Manufacturing Needs
EOS aluminium powders are designed and rigorously tested for use on EOS metal 3D printers, ensuring consistent quality for your most demanding applications.
These alloys help overcome the typical challenges of traditional manufacturing by enabling part consolidation, intricate internal channels, and lightweight designs that don't sacrifice strength.
EOS Aluminium AlSi10Mg and EOS Aluminium AlF357 are Premium materials and are shipped with an inspection certificate (EN 10204, Type 3.1 or 2.2) detailing the results of extensive QA testing. EOS Aluminium Al2139 AM and Al5X1 are Core materials, shipped with a material test report (EN 10204, Type 2.2) showing QA results for chemical properties and particle size distribution.
Typical Aluminium Part Properties
Manufacturers select aluminium alloys for metal 3D printing based on a combination of key properties, a high strength-to-weight ratio being the most prominent one. This applies especially in the aerospace industry and automotive sector, where reducing mass without compromising structural integrity is the top priority. Corrosion resistance, thermal conductivity for heat management, and electrical conductivity open up even more use case scenarios across defense, marine, and general engineering environments. Post-processing options like anodizing then allow for applications requiring one of those features in addition to a distinct final surface finish.
Typical Part Properties
- Chemical Composition Standard Designed for AM
- Tensile Strength 410 MPa
- Yield Strength 380 MPa
- Elongation at Break 14 %
EOS Aluminium Al5X1
A High-Strength Aluminium Alloy With Good Corrosion Resistance
EOS Aluminium Al5X1* is a heat-treatable aluminium alloy designed for the 3D printing process, offering a compelling combination of high strength and high elongation. The recommended single-step heat treatment does not require a water quench of the 3D-printed part and enables robust build quality.
Al5X1’s combination of high elongation and corrosion resistance makes it particularly well-suited for structural aerospace brackets and marine components exposed to harsh operating environments.
Highlights
- Excellent combination of strength & elongation
- Good corrosion resistance
- Aluminium parts can be anodized
Typical Applications
- Aerospace
- Automotive
- Marine
- Lightweight designs
Compatible Printers
Typical Part Properties
- Chemical Composition Standard AlSi7Mg0.6, SAE AMS 4289
- Tensile Strength 330 MPa
- Yield Strength 260 MPa
- Elongation at Break 11 %
EOS Aluminium AlF357
Lightweight Metal Powder for the Aerospace Industry and More
EOS Aluminium AlF357 is an ideal material for 3D printing applications requiring a combination of low weight and mechanical/thermal load endurance. It’s a beryllium-free derivative of the A357 (AlSi7Mg0.6) alloy. Parts built of EOS Aluminium AlF357 can be machined, shot-peened and polished in the as-built or heat treated state. For this product, a T6-like heat treatment may be utilized to enhance the overall mechanical properties.
AlF357’s beryllium-free composition and SAE AMS 4289 compliance make it a preferred choice for aerospace structural components where both regulatory compliance and high dynamic load performance are non-negotiable.
Highlights
- Light-weight
- Corrosion resistance
- High dynamic load bearing capacity
Typical Applications
- Aerospace industry applications
- Defense and automotive industries
- Structural components requiring high strength
Typical Part Properties
- Chemical Composition Standard AlSi10Mg
- Tensile Strength 460 MPa
- Yield Strength 245 MPa
- Elongation at Break 5 %
EOS Aluminium AlSi10Mg
Responsible Product With Modifiable Material Properties
Parts printed using EOS Aluminum AlSi10Mg offer good strength, hardness and dynamic properties as well as good thermal properties and low weight. As a Responsible Product the 3D printing material incorporates a 100% recycled aluminium feedstock achieving a 83% CO2e reduction.
AlSi10Mg is one the most widely adopted aluminium alloys in metal 3D printing. Its versatility - combined with EOS’s 100% recycled feedstock option - makes it a strong fit for manufacturers looking to replace traditional cast parts while meeting sustainability targets.
Highlights
- Good strength, hardness and dynamic properties
- High corrosion resistance
- Good thermal and electrical conductivity
- Properties modifiable with heat treatment
Typical Applications
- General engineering components and parts subject to high loads
- Lightweight designs
- Aerospace and automotive components
- Substitution of cast AlSi10Mg parts
Compatible Printers
Typical Part Properties
- Chemical Composition Standard modified from Aluminum Association Teal Sheet for Al2139
- Tensile Strength 520 MPa
- Yield Strength 460 MPa
- Elongation at Break 4 %
EOS Aluminium Al2139 AM
Pure Aluminium Performance in Elevated Temperatures
EOS Aluminium Al2139 AM is a 2000-series high-strength alloy specifically designed for metal additive manufacturing. It demonstrates outstanding performance in elevated temperatures up to 200°C. Excellent strength properties include yield and tensile strength around 500 MPa in heat-treated state and allow lightweight part design. The fast and simple heat treatment procedure enables an affordable part production at a higher build volume.
Al2139 AM’s elevated-temperature performance positions it for under-hood automotive and racing applications where aluminium alloys typically fall short, as well as aerospace components exposed to sustained thermal loads.
Highlights
- Unmatched strength in temperatures between 50 and 200 °C
- Robust one-step heat treatment
- Post-processing options, including electropolishing and anodization
Typical Applications
- Aerospace
- Racing
- Transportation and Mobility
- Lightweight designs
Compatible Printers
Typical Part Properties
- Chemical Composition Standard AA8A61.50
- Tensile Strength 340 MPa
- Yield Strength 300 MPa
- Elongation at Break 11 %
EOS Aluminium Constellium CP1
Highlights
- High strength with good ductility
- Good electrical and thermal conductivity
- Excellent corrosion resistance
- Easily anodized due to its silicon-free composition
- Simplified heat treatment with no quenching required
Typical Applications
- Heat exchangers
- Components requiring high-quality surface finishing, polishing, and anodization
- Parts exposed to corrosive environments
- Semiconductor industry applications
- Lightweight structural components with moderate mechanical load requirements
Compatible Printers
Book a Consultation With Our Additive Manufacturing Experts To Find the Right 3D Printing Options for Your Needs
Choosing the right material and manufacturing process is critical to your project's success. Our team of AM experts is here to help you navigate the options and find the perfect combination of material, process, and system to meet your goals. In case our offering doesn’t already include the right option for your use case, our experts will happily help you discuss customized materials.
Contact us today to discuss your application and learn how EOS aluminum 3D printing can work for you.
