In the evolving world of Additive Manufacturing (AM), precision, performance, and material integrity are critical. One of the most transformative developments in this field is the ability to 3D print pure copper and copper alloys with high electrical and thermal conductivity — materials once considered extremely challenging due to their reflectivity and thermal behavior.

Thanks to the advancements in EOS metal 3D printing systems, particularly the EOS M 290 with 1kW laser configuration developed by AMCM (an EOS Group company), manufacturing complex, high-performance copper parts is now a reality.

Why Print with Pure Copper?

Pure copper is renowned for its exceptional conductivity, but its high reflectivity and thermal conductivity pose significant hurdles in laser-based 3D printing. EOS has overcome this with tailored process parameters and specialized hardware:

Copper and its alloys are vital for applications such as:

• Heat exchangers
• Electrical connectors and windings
• Rocket engine components
• Induction coils
• Marine impellers

Traditionally, producing complex geometries in these materials was time-consuming, wasteful, and restrictive. With Direct Metal Laser Solidification (DMLS), EOS enables geometrical freedom, material efficiency, and functional performance — redefining how copper is used in manufacturing.

EOS Copper Portfolio at a Glance

EOS Copper Cu (Pure Copper for EOS M 290 – 400W Laser)

• Conductivity: >90% IACS (heat-treated)
• Mechanical Strength: 180 MPa yield, 200 MPa tensile
• Layer Thickness: 20 µm
• Use Case: Early adoption and R&D for heat exchangers, electronics

A solid choice for foundational pure copper applications where moderate build rates and high conductivity are essential.

EOS Copper CuCP (Commercially Pure Copper for AMCM M 290 – 1kW Laser)

• Purity: >99.95%
• Conductivity: Up to 102.6% IACS (heat-treated)
• Elongation at Break: Up to 55%
• Layer Thickness: 40 µm
• Volume Rate: 5.4 mm³/s
• TRL: 5
• Use Case: Inductors, high-current connectors, electric motors

With dual exposure strategies (bulk and application-specific), CuCP balances conductivity, productivity, and repeatability — even across multiple powder reuses.

EOS CopperAlloy CuCrZr (Strength + Conductivity for AMCM M 290 – 1kW Laser)

• Yield Strength (HT): 210 MPa
• Tensile Strength (HT): 340 MPa
• Conductivity (HT): >80% IACS
• Volume Rate: 15.4 mm³/s
• Layer Thickness: 80 µm
• Use Case: Rocket nozzles, high-stress coils, heat sinks

An ideal choice for components requiring durability under heat and pressure — bridging structural integrity with electrical function.

EOS Copper Alloy CuNi30 (Saltwater-Resistant Alloy for EOS M 290 & M 400-1)

• Excellent corrosion resistance in salt water
• Yield Strength (HT): Up to 560 MPa
• Tensile Strength (HT): Up to 700 MPa
• Layer Thickness: 60 µm
• Volume Rate: 5.2 mm³/s
• Use Case: Marine parts, impellers, offshore pump housings

CuNi30 offers marine-grade protection and strength — performing reliably even in low temperatures and aggressive environments.

Built on the EOS Quality Triangle

Every material developed by EOS aligns with its Quality Triangle: System, Material, and Process. This ensures consistent, repeatable results — whether you’re building a powertrain coil, a marine pump, or a next-gen electric drive.

From TRL 3 exploratory materials to TRL 7+ validated products, EOS supports the entire adoption curve — from research to production.

Real Impact, Real Innovation

EOS metal systems make what was once impossible, now industrially viable:

• High conductivity copper parts printed directly, with minimal post-processing
• Optimized exposure strategies for delicate features like windings and thin walls
• Heat treatments tailored for specific mechanical and thermal outcomes
• Minimized defects, even after multiple powder reuses

The convergence of material science, laser power, and process know-how empowers designers and engineers to innovate without constraint.

EOS Metal Systems: Tailored for Copper Printing

EOS doesn’t just supply powders — it delivers a complete solution. Their Quality Triangle approach integrates system, material, and process, ensuring consistent output across industries. EOS M 290 configurations (standard and 1kW variants) deliver:

• Closed-loop thermal monitoring
• Precision recoating mechanisms
• Software-controlled exposure profiles
• Compatibility with argon-protected atmospheres for material purity

Final Thoughts: Applications Driving Demand

Industries such as aerospace, automotive, energy, and electronics are increasingly adopting copper AM parts for:

• Weight-optimized heat sinks and exchangers
• Compact, complex geometries in RF and inductive components
• Conformal cooling and embedded circuitry in power systems

By enabling the additive manufacture of high-conductivity copper and alloy parts, EOS empowers engineers to design for function without compromise — ushering in a new era of metal AM performance.