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Advanced Manufacturing

Advanced manufacturing Technology

We provide advanced manufacturing services in technologies like 3d printing, CNC machining, fabrication, and extrusion.

Experienced Engineers


Team of expert engineers with more than 15 years of experience.

On Time Project Delivery

on time project delivery


With locations in all over Australia we can assure lightning fast delivery.

Australia Wide Expandation

Australia wide expandation


Zeal 3D is present in
Victoria, NSW, Western Australia,
Queensland and Tasmania.

ISO 9001 : 2015

ISO 9001-2015 certified


Committed to consistently provide products and services that meet customer and regulatory requirements and to demonstrate continuous improvement.

Aluminium 3D printing

Aluminium is a non-corrosive, lightweight, strong, flexible, and endlessly recyclable metal that is frequently used in industrial sectors such as transportation, building, manufacturing, and much more. Due to its outstanding characteristics, this aluminum material is a perfect choice for high-performance functional prototypes that are subjected to a lot of stress. Aluminum is utilized in metal 3D printing or additive manufacturing to create 3D printed aluminum parts, primarily for the aerospace and marine industries.

Aluminium is widely used in the additive manufacturing process since it is lightweight and possesses strong thermal characteristics. In the aluminum 3D printing process, aluminium powder is sintered with a laser to generate metal pieces that are just as excellent as machined models. Unlike conventional shiny milled metal, 3D-printed aluminum is not shiny, thereby giving it an aesthetic and classic look. In addition, one of the main benefits of 3D printing in aluminum is the ability to produce pieces with interior grooves and features that can't be produced in any other method.

3D Printed Aluminium Parts
Aluminium 3D Printing

Benefits Of Using Aluminum for 3D Printing

  • Alloys made of aluminium provide excellent material qualities that are suitable for a wide range of 3D engineering applications. For instance, aluminium gives adequate strength and hardness while being lighter when compared to nickel and steel-based alloys.
  • Besides having strong corrosion resistance, aluminium alloys also have good thermal characteristics.
  • With a weight of about 2.7g/cm3 and one-third that of steel, aluminium is one of the lightest naturally occurring solid metals. Due to its lightweight, aluminium is frequently used in 3D metal printing methods in order to make high-end, lightest, and aesthetically appealing components.
  • Aluminium additive printing makes it possible to create highly optimised structures that would otherwise be expensive, time-consuming, or even impossible to manufacture using traditional manufacturing techniques. In addition, 3D-printed aluminium parts mixed with other materials can be used to create hybrid designs and structures.

Aluminium Alloys

One of aluminium's most important characteristics is its propensity to combine with other substances. Despite being ductile and soft in its pure form, aluminum undergoes a significant shift in properties when mixed with other metals. Aluminium alloys are divided into a wide range of categories based on the properties of the specific material, such as how it responds to thermal and mechanical treatment and the principal alloying element added to the aluminum alloy. In addition, an aluminum alloy series has been created for aluminium alloys based on their composition. Below given are some of the most important series of aluminium alloys.

1000 Series

With a minimum 99 percent aluminium composition, the 1000 series represents the purest of all commercially available aluminium alloys. Because of the material's resistance to corrosion, this group of aluminium alloys is preferred in various industrial manufacturing operations. The 1000 series aluminum alloys possess fundamental characteristics like tall corrosion resistance, increased electrical and thermal conductivity, and flexible workability. However, welding 1000 series aluminium alloys require some pre-welding concerns due to the material's limited melting range. Some of the most popular aluminum alloys that belong to the 1000 series are,

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  • Aluminium Alloy A91050
  • Aluminium Alloy A91100
  • Aluminium Alloy A91180
  • Aluminium Alloy A91199
  • Aluminium Alloy A91350

2000 Series

The 2000 series aluminium grades are sometimes known as copper grades of aluminium since copper serves as the main alloying element. Copper is added to an alloy to boost its strength and hardness, which also improves its machinability. Because of their strength and lightweight, they are also used to make precision instruments. When lightweight and good mechanical qualities are required, these alloys can be combined with magnesium and manganese. Due to their weak corrosion resistance, these alloys may be seamlessly coated or plated. Furthermore, these types of aluminum alloys are utilized for activities demanding high strength/weight ratios up to 150 °C. Some of the most popular aluminum alloys that belong to the 2000 series are,

  • Aluminium Alloy A92011
  • Aluminium Alloy A92017
  • Aluminium Alloy A92024
  • Aluminium Alloy A92048
  • Aluminium Alloy A92219

3000 Series

Manganese serves as the primary alloying element in the 3000 family of aluminium alloys, offering reduced ductility and excellent mechanical resistance. The 3000 series aluminium alloy has more strength than pure aluminium alloy, despite the fact that it cannot be heat treated. However, it exhibits good plasticity after annealing and cold treatment (under-cold rolling mill). Due to its great corrosion resistance and welding capabilities, it can be employed in a wide variety of industries, including the building and decoration industry, the electronic manufacturing industry, the automobile manufacturing industry, etc. Some of the most popular aluminium alloys that belong to the 3000 series are,

  • Aluminium Alloy A93003
  • Aluminium Alloy A93004
  • Aluminium Alloy A93105
  • Aluminium Alloy A93005
  • Aluminium Alloy A93102
  • Aluminium Alloy A93103

4000 Series

The primary alloying component of the 4000 series aluminium alloy is silicon. Due to their high silicon concentration, lower melting point, good melt fluidity, and lack of brittleness, this family of alloys is largely used to produce aluminium alloy welding additives, such as welding rods, brazing plates, and welding wire. Furthermore, some of the alloys in this series are utilized to create pistons and heat-resistant components due to their excellent wear resistance and high-temperature performance. Some of the most popular aluminium alloys that belong to the 4000 series are,

  • Aluminium Alloy A94006
  • Aluminium Alloy A94007
  • Aluminium Alloy A94015
  • Aluminium Alloy A94032
  • Aluminium Alloy A94043
  • Aluminium Alloy A94047

5000 Series

One of the most popular and efficient alloying agents for aluminium is magnesium, which serves as the main constituent of alloys in the 5000 series. These alloys range from moderate to high strength, are non-heat treatable, easily weldable, and exhibit excellent corrosion resistance, especially in marine applications. Some of the most popular aluminum alloys that belong to the 5000 series are,

  • Aluminium Alloy A95052
  • Aluminium Alloy A95083
  • Aluminium Alloy A95086
  • Aluminium Alloy A95454
  • Aluminium Alloy A95754

6000 Series

In the 6000 series of aluminium alloys, silicon and magnesium are the two principal alloying components. 6000 alloys stand out for their extrudability, excellent strength, and exceptional corrosion resistance. These types of alloys can be formed easily and are also easy to deal with, machinate, and weld. They are used for general-purpose welded structures, architectural uses, and motorcycle and bicycle frames. Some of the most popular aluminum alloys that belong to the 6000 series are,

  • Aluminium Alloy A96005
  • Aluminium Alloy A96013
  • Aluminium Alloy A96061
  • Aluminium Alloy A96063
  • Aluminium Alloy A96101

7000 Series

Commercial aluminium alloys from the 7000 series primarily contain zinc as an alloying element. When these alloys are combined with a lesser amount of magnesium, a very robust heat-treatable alloy is produced. Due to their exceptional mechanical robustness and lightness, these types of aluminium alloys are used in aerospace, automotive, and architecture industries. Some of the most popular aluminum alloys that belong to the 7000 series are,

  • Aluminium Alloy A97010
  • Aluminium Alloy A97050
  • Aluminium Alloy A97068
  • Aluminium Alloy A97075
  • Aluminium Alloy A97175

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3D Printed Aluminum Part
3D Printed Aluminum Parts for Aerospace Industry

Applications of Aluminium in Various Industries

Aerospace Industry

Aluminium is ideal for producing aircraft parts because it is both lightweight and durable. Aluminium makes up a third of the weight of steel, allowing aircraft to carry more cargo or burn less fuel. Additionally, aluminium's outstanding corrosion resistance ensures the safety of the aeroplane and its passengers. The material properties of aluminium make it the perfect choice for several applications in a variety of industries, including aerospace and aviation.

Some of the popular grades of aluminium used in the aerospace industry are,

  • Al 2017
  • Al 2024
  • AI 3003
  • AI 5052

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  • AI 6013
  • AI 6050
  • AI 6061
  • AI 7075

Types of aerospace products made with aluminium are,

  • Fuselage skins
  • Stringers and bulkheads
  • Wing spars and ribs
  • Wing skins
  • Panels and covers
  • Seat ejectors
  • Wing leading edge
  • Rear legs of seat
  • Seat spreaders
  • Floor sections of the aircraft
  • Sear structure

Marine Industry

Aluminium alloys are employed in the maritime industry because they are strong, light, and have great mechanical properties for parts fabrication in offshore platforms and shipbuilding. Due to its many beneficial characteristics, marine-grade aluminium is especially well suited for building seagoing vessels and structures as well as the machinery and components used within them.

Some of the popular grades of aluminium used in the marine industry are,

  • AI 5083
  • AI 5052
  • AI 5086
  • AI 5454
  • AI 5456
  • AI 5754
  • AI 6082
  • AI 6061
  • AI 6060

Types of marine products made with aluminium are,

  • Boat body parts
  • Beams
  • Boat lifts
  • Docks and Braces
  • Ladders
  • Railings
  • Gratings
  • Windows and doors
  • Hulls
  • Deck houses
  • Hatch covers

Medical Industry

Aluminium offers the versatility and durability required for medical equipment to be long-lasting. Aluminium has demonstrated its adaptability in design, recyclable nature, lightweight, low production costs, and strength-to-weight ratio in the medical industry. Because of aluminium's high thermal conductivity, instruments dry quickly, reducing the spread of bacteria over moist surface areas. Additionally, it is the best metal to use for large production runs.

Some of the popular grades of aluminium used in the medical industry are

  • AI 3003
  • AI 6061
  • AI 6063

Types of medical components made with aluminium are,

  • Surgical Devices
  • Stethoscopes
  • Cases
  • Containers
  • Trays
  • Tubes for diagnostic equipment
  • Lamps
  • Saws
  • Scalpels

Defence Industry

Due to its lightweight characteristics, aluminium is a significant component of alloys used in defence aviation, electrical systems, and navigation radars. Furthermore, aluminium extrusions are the perfect material for defence applications since they possess a high strength-to-weight ratio, outstanding wear resistance, toughness, resistance to corrosion, and good machinability. In addition, aluminium's ability to reflect radiant energy, especially UV rays, is another quality that makes it so crucial in military and defence applications. Because of this, aluminium works well as solar radiation insulation in aircraft.

Some of the popular grades of aluminium used in the defence industry are

  • AI 7050
  • AI 7068
  • AI 7075

Types of military components made with aluminium are,

  • Artillery
  • Military Armour
  • Missile Casings
  • Panelling
  • Airframe wings
  • Landing gears
  • Frigates
  • Fuselages Battle tanks
  • Infantry fighter vehicles

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Services We Offer for Aluminium Material

3D Printing

Aluminium is a lighter metal with remarkable thermal characteristics, high flexibility, and good strength. Due to its high-end qualities, it has evolved as the primary metal utilized in 3D printing. Aluminium 3D printing processes are widely employed in the biomedical, automotive, and aerospace industries compared to any other metal 3D printing. The primary strength of 3D printing aluminium alloys is their pliability for moulding and use in functional prototypes. Because of its exceptional properties, this metal material is an excellent choice for high-performance functional components that must withstand high pressures.

CNC Machining

Due to its great machinability and popularity in the majority of manufacturing industries, aluminium is the material that is most frequently machined. The aluminium metal can be machined into the desired shape quite easily, especially during machining procedures like CNC aluminium machining.

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In a conventional manufacturing process called CNC machining, excess material is removed from a solid block of material using drills and turning tools in order to get the desired end product. This method is quick, incredibly reproducible, and great for making parts with precise tolerances. Any material that is rigid enough to mill can be used for CNC machining, including plastic, metal, and fiberglass. However, because of its lightweight and attractive qualities, aluminium is commonly chosen by product teams.

Fabrication

Aluminium fabrication is the process of moulding aluminium into a final product, like a solar panel component or an outdoor enclosure. Aluminium is fabricated using a variety of techniques, including welding, hammering, stretching, extruding, and shearing. Aluminium is a desirable material for manufacturing because, in comparison to other types of metal, it is lightweight, corrosion-resistant, strong, non-sparking, and non-magnetic. It is a lightweight material with a greater strength-to-weight ratio that weighs only a third as much as stainless steel. Due to its relative softness, resistance to corrosion, and ability to be recycled, aluminium is also a simple metal to fabricate or work with.

Extrusion

Extrusion of aluminium is the process of forcing an aluminium alloy material through a die having a particular cross-sectional profile. In the extrusion method, the metal is forced through the die by a strong ram coming out of the die aperture. As a result, extruded metal emerges from the die in the same shape and is drawn out along a runout table. The process of aluminium extrusion can create items with extraordinary precision, accuracy, and tolerances. From the initially extruded aluminium portion to the last, there are no differences in length or measurement between any two extruded profiles.

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Aluminum AISi7Mg06 3D Printed Part
Aluminium 3D Printed Hinge Bracket A320

Why Choose Zeal 3D?

One-Stop Solution: Zeal 3D, an ISO 9001-2015 certified company, offers a wide variety of 3D engineering solutions and digital manufacturing services, including 3D printing, vacuum casting, laser cutting, CNC machining, and CAD services to help you achieve all of your organizational goals.

Extensive Material Support: Zeal provides a wide range of 3D printing materials for plastic and metal 3D engineering to completely meet all of your business and industrial needs. We print in more than 40 different materials, such as aluminium, copper, stainless steel, plastic, and brass, using a range of 3D printing techniques, such as FDM, SLS, SLA, SLM & DMLS, and more.

On Demand Services: Zeal 3D services offer an extensive range of on-demand and fast prototyping services to assist manufacturers and designers in swiftly, affordably, and securely developing and testing industrial products. At Zeal 3D, we can take your concept or design and transform it into reality in a matter of days using cutting-edge quick prototype technologies like 3D printing, CNC machining, and vacuum casting.

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Instant Quoting: With the help of our exceptional 3D engineering services, Zeal 3D can turn your concept into a workable reality.

Contact us right now for a quick, free quote based on the needs of both your customers and your company.

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