Copper in 3D Metal Printing

Highest electrical and thermal conductivity in additive metal printing. Copper and copper alloys are suitable for components where heat transfer or electrical conductivity are key considerations.

Very high electrical conductivity (pure copper)
very good thermal conductivity
Complex cooling channels can be incorporated into a single component

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Product Visualization, AI-Generated

Is copper the right material for your component?

Copper is particularly suitable when …

Electrical conductivity is the primary requirement
Heat transfer or close-contour cooling is crucial
complex cooling channels that cannot be manufactured using conventional methods are required
inductors or electromechanical components are to be manufactured
the technical benefits justify the comparatively high manufacturing costs

Consider alternatives if …

Component weight is a key factor
high mechanical strength is the primary consideration
the lowest component price is the deciding factor
high operating temperatures occur
Corrosion resistance is sufficient at a lower cost

Suitable Alternatives

CuSn10 bronze, when wear resistance and surface finish are more important than maximum conductivity. Learn more
Aluminum, when weight and cost-effectiveness are the top priorities. Learn more about aluminum
Stainless steel 1.4404, when a robust standard material is required. About stainless steel

Copper in Comparison

Decision criterion	Copper	Bronze CuSn10	Aluminum AlSi10Mg	Stainless steel 1.4404
Weight	very high	high	least	high
Strength	low–medium	medium	medium	high
Electrical Conductivity	very high	medium	good	low
Thermal Conductivity	very high	medium	good	low
Corrosion Resistance	good	good	good	very good
Cost item	high	medium–high	relatively inexpensive	medium
A typical decision	maximum conductivity	Wear & Surface	cost-effective lightweight construction	robust standard application

In short: Copper is the right choice when electrical or thermal conductivity is a priority. Bronze is usually the better option for wear resistance and surface quality, while aluminum is generally the better choice for cost-effective, lightweight construction.

Copper at a Glance

The material with the highest electrical and thermal conductivity in additive metal printing—for components where conductivity is the key requirement.

Typical copper components:

current-carrying contacts and contact carriers
Heat sinks and contour-following cooling structures
Sliding and Wear Parts
electromechanical components
Coil and Inductor Bodies
Heat Exchanger

Typical applications:

Electrical Engineering,
Electronics/Thermal Management,
Induction hardening,
Mechanical Engineering,
Energy Technology.

Material variant	CuNi2SiCr (standard) or Cu-ETP pure copper (maximum conductivity)
Density (CuNi2SiCr)	~ 8.2–8.3 g/cm³
Tensile Strength_Rm (CuNi2SiCr)	~ 251 ± 10 MPa
Yield strength_Rp0.2 (CuNi2SiCr)	~ 192 ± 10 MPa
Elongation at break A (CuNi2SiCr)	~ 8–9%
Modulus of Elasticity E (CuNi2SiCr)	~ 34,000 ± 5,000 MPa
Electrical Conductivity (Cu-ETP)	up to ~ 58 MS/m
Thermal Conductivity (Cu-ETP)	~ 400 ± 15 W/(m·K)
Installation space (copper)	280 × 280 × 360 mm
Tolerances (Approximate Values)	±0.2 mm or ±0.2% (whichever is greater)
Surface	blasted / polished; CNC precision machining upon request

The values listed are approximate. Actual properties may depend on factors such as component orientation, wall thickness, process parameters, and heat treatment, among others.

Designing Copper Parts for 3D Printing

In 3D printing with copper, the design affects not only manufacturability but also part quality, costs, and the amount of post-processing required. Therefore, part orientation, support structures, powder removal, and functional surfaces to be machined later should be taken into account as early as the development stage.

Cavities and internal channels

Internal channels and complex cavities are among the particular strengths of additive manufacturing. However, it must be possible to completely remove any unmelted metal powder after the manufacturing process.

Enclosed cavities should therefore be avoided. For internal structures, sufficiently large and easily accessible powder inlets must be provided. The shape, length, and configuration of the channels must allow for reliable emptying.

Wall thicknesses and delicate areas

Wall thicknesses must be tailored to the size, geometry, and load-bearing requirements of the component. Structures that are too thin or have a large surface area may deform during manufacturing. Solid sections, on the other hand, increase material usage, construction time, and thermal stress.

Uniform material distribution and smooth transitions are generally preferable to sharp changes in cross-sectional dimensions. Fillet radii can help reduce local stress peaks.

Overhangs and Support Structures

Overhanging areas require additional support structures, depending on their angle, length, and orientation. These structures stabilize the component during the construction process and dissipate process heat.

Since support structures must be removed after manufacturing, they should be placed on easily accessible and non-critical surfaces whenever possible. The orientation of the component therefore has a direct impact on:

the number of support structures required
the surface quality
the amount of post-processing required
the construction time and, consequently, the production costs
the location of mechanically and visually relevant surfaces

Holes, Threads, and Fits

Holes and threads can be incorporated into the design. If tight dimensional tolerances, defined fits, or load-bearing threads are required, mechanical finishing is often recommended.

To ensure this, the relevant areas should be designed with an appropriate machining allowance. This applies in particular to:

Fit holes
Thread
Bearing and Seal Seats
Planned Areas
Connection surfaces
precise contours

A technical drawing that includes tolerances and functional surfaces makes production planning easier.

Distortion and Thermal Stresses

Layer-by-layer melting and solidification result in significant local temperature differences. These can cause residual stresses and warping. Large, flat surfaces, abrupt changes in cross-section, and uneven material distribution are particularly critical.

These effects can be reduced through proper component orientation, design adjustments, and subsequent heat treatment.

Design data for testing

For the manufacturing review, you can submit your 3D model in STEP, STL, or 3MF format. For fits, threads, sealing surfaces, and geometric and dimensional tolerances, a technical drawing in PDF format should also be provided.

Are you still in the design phase? We review component orientation, critical geometries, post-processing, and potential cost optimizations before manufacturing begins.

Manufacturing, Build Volume, and Tolerances: Important Information for Optimal 3D Printing

Rapidobject processes copper using powder-bed-based metal 3D printing. For most applications, the CuNi2SiCr alloy—which prints well—is used; for maximum electrical or thermal conductivity, pure copper (Cu-ETP) is also available, although it is more challenging to process.

Materials and Manufacturing Processes:

Manufacturing process: powder-bed-based metal 3D printing
Typical finish: sandblasted
Further processing: Trowalizing, polishing, and CNC finishing according to technical specifications

Post-processing Options

3D Printing

Heat Treatment	Stress-relief annealing as needed
Blasting/Trowalizing/Polishing	uniform, matte to high-gloss finish
CNC Finish	Flat surfaces, holes, threads, contact surfaces
Labeling	Serial number/logo available
Documentation	Test report/measurement report available upon request

CNC Re-machining

Mating surfaces,
Drilling,
Thread,
Seal Grooves

– Everything from a single source. Just upload your drawing.

How do I get a quote?

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You will receive a detailed price list for all materials and surface finishes.

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Frequently Asked Questions About 3D Metal Printing with Copper

When is copper a better choice than bronze?

Copper is the right choice when maximum electrical or thermal conductivity is required, such as in contacts, inductors, or cooling structures.

If, on the other hand, wear resistance and a surface that can be polished to a high gloss are the primary considerations, CuSn10 bronze is usually the more suitable choice and easier to work with.

How does the CuNi2SiCr copper alloy differ from pure copper (Cu-ETP)?

CuNi2SiCr can be easily processed using the SLM method and offers sufficient electrical conductivity for many applications, combined with good mechanical strength.

Pure copper (Cu-ETP) offers significantly higher electrical and thermal conductivity, but its high laser reflectivity makes it more challenging to manufacture. The appropriate option depends on the specific requirements.

For which components is copper suitable in 3D printing?

Copper is particularly well-suited for components where electrical conductivity is a priority. Typical examples include:

current-carrying contacts and contact carriers
Heat sinks and contour-following cooling structures
Coil and Inductor Bodies
Heat Exchanger

For components subjected solely to mechanical stress and with no electrical conductivity requirements, a different material is usually more cost-effective.

What levels of electrical and thermal conductivity does copper achieve in 3D printing?

In 3D printing, pure copper (Cu-ETP) achieves an electrical conductivity of up to ~58 MS/m and a thermal conductivity of approximately ~400 W/(m·K). These values are to be considered approximate.

The CuNi2SiCr copper alloy has lower electrical conductivity—though sufficient for many applications—and offers better mechanical strength.

What is the surface finish of copper parts immediately after 3D printing?

After additive manufacturing, copper parts have a rough surface due to the manufacturing process. At Rapidobject, the parts are sandblasted as standard, resulting in a uniform, matte finish.

Upon request, we can also provide polishing or CNC finishing of contact and functional surfaces.

Can threads and fits be printed directly?

Threads, holes, and fits can be incorporated into the 3D model. However, if specific dimensions or tight tolerances are required, subsequent machining is often recommended.

The relevant areas should therefore be designed with a machining allowance and marked on a technical drawing. For example, threads can be cut, holes can be reamed, or mating surfaces can be milled.

What data formats are accepted?

STL, STEP, and 3MF. For CNC machining, please also provide a technical drawing as a PDF.

How soon will I receive my quote?

Usually immediately after upload—complex assemblies are analyzed automatically.

What types of post-processing are possible?

Blasting, Trowalizing, Polishing, Milling/Facing, Drilling, Threading, Surface Marking.

Are there any volume discounts?

Yes. For orders of more than 2 units, we offer automated volume-based pricing; for recurring orders, framework agreements are available.

Do you have any questions?

We’d be happy to provide you with personalized advice on your 3D printing project—from the initial idea to the finished part.

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Is copper not the best fit for your needs?

Compare Copper to Other Metals

Copper offers the highest electrical and thermal conductivity of all our metallic materials. For components where other factors—such as wear resistance, weight, or cost-effectiveness—are a priority, a different material may be the more suitable choice.

Therefore, determine which property is most important for your application.

Do you need maximum strength with minimal weight?

Titanium

Titanium TiAl6V4 combines very high strength with relatively low weight and excellent corrosion resistance. It is particularly well-suited for demanding, weight-optimized functional components.