Both cover the full powder metallurgy spectrum and both are sinter-based two-step processes. CMF integrates the metal powder in a polymeric binder, so safety requirements are lower and the binder supplies flowability. Binder jetting uses pure metal powder, needs higher safety measures, and requires the powder itself to flow. CMF prints on any SLS polymer printer; binder jetting needs a process-specific machine.
CMF layers run 70 to 120 microns, typically 100. High green part strength means post-processing and automation are possible, and sinter shrinkage is even at 13 to 14% in X, Y and Z. Binder jetting runs 35 to 100 microns but lower green strength makes post-processing difficult, and shrinkage is uneven at 17 to 26%.
Both reach isotropic grain structure and relative density above 97%, with properties like MIM parts. CMF handles small to large solid parts up to several kilograms and green parts can be smoothed and joined. Binder jetting is limited to small and medium parts with a greater weight limitation. Different cost structures, similar cost per cubic centimetre: CMF is low capex against high output with binder cost inside the feedstock, binder jetting is high capex with binder cost on top of the powder.
The decision usually comes down to part size, part weight, and whether you need to touch the green part before it becomes metal.
CMF gives the full powder metallurgy spectrum. LB-PBF is limited to weldable materials: stainless and tool steels, titanium alloys, aluminium alloys. CMF is sinter-based on SLS polymer printers with no build plate and no supports. LB-PBF melts metal directly on metal printers and requires support structures.
CMF produces an isotropic grain structure, density above 97% and up to 99.9% for liquid-phase alloys, and usually higher elongation. LB-PBF produces an anisotropic grain structure, density above 99.5%, and usually higher tensile strength. CMF needs no stress relief because printing temperature is low; LB-PBF usually does.
CMF is built for series production with a sweet spot from 100 to 100,000 parts, high build speed and output, on SLS printers from EUR 5,000 plus debinding and a sintering furnace. LB-PBF suits prototyping and small series, 1 to 1,000 parts, with low build speed and high machine cost plus post-processing and often a heat treatment furnace.
Metal AM sample prices are often quoted assuming full machine utilisation, unrealistic packing density, material at very high volume, no personnel or post-processing cost, and zero scrap. Put every real cost in, from powder to finished part, and send us the part. We will run your numbers rather than ours.
