Metal FDM Filament

Aluminum 6061 Filamet™ — 1.75 mm, 0.5 kg

Print real lightweight aluminum metal parts on the FDM printer you already own. After kiln firing, your print becomes 60–69% pure 6061 aluminum — the alloy used in aerospace structures, bicycle frames and lightweighting applications.

60–69% Aluminum 6061 Lightest TVF Metal Aerospace Alloy Lightweighting Prints Like PLA
The Virtual Foundry Aluminum 6061 Filamet 1.75mm 0.5kg spool

Real 6061 aluminum, printed on a desktop FDM printer

Aluminum 6061 Filamet™ is the lightest metal-loaded filament in the TVF range — density of just 1.20–1.50 g/cc, similar to PLA. After sintering, finished parts are 60–69% pure 6061 aluminum — the alloy used in aerospace structures, bicycle frames, automotive components and architectural cladding.

Because the filament is so much lighter than copper or steel Filamets, snap risk at the extruder is significantly lower — 6061 prints almost as forgivingly as PLA itself. Sinters at lower temperatures than steel but higher than bronze.

Why aluminum FDM matters. Aluminum is famously hard to 3D print at industrial scale — melt-pool processes (DMLS, SLM) often produce porous parts. The TVF print-then-sinter approach bypasses the melt pool entirely, giving you genuine 6061 from a desktop FDM printer.

How it works — the 4-step process

1

Print

Print on any FDM printer with a hardened steel nozzle. Aluminum is the lightest TVF metal — prints almost like PLA.

2

Pack

Nest the green part in refractory ballast inside an alumina crucible. Aluminum benefits from a tightly packed crucible.

3

Sinter

Fire to ~600–650°C in a kiln. Aluminum sinters at much lower temperatures than steel — even an entry-level kiln can handle it.

4

Finish

Brush off ballast, machine, polish, anodise or paint. Expect ~15–20% linear shrinkage — design for it by scaling up ~120–125% in your slicer.

Why 6061 aluminum

Lightest TVF metal

Density of 1.20–1.50 g/cc — close to PLA. Lower extruder load means easier printing on any FDM machine.

Aerospace pedigree

6061 is the workhorse aluminum alloy of aerospace, automotive, bicycle and consumer hardware industries.

Lower sintering temp

Aluminum sinters at ~600–650°C — well within range of even entry-level kilns and pottery kilns.

Anodisable + machinable

Sintered parts can be machined, polished, anodised or painted using standard aluminum finishing workflows.

Lower density = lighter parts

Where weight matters — drones, RC, lightweight prototypes — aluminum is the obvious choice.

USA-made, fully supported

Manufactured in South Central Wisconsin by The Virtual Foundry. Direct technical support from the team that makes the material.

Specifications

Specification Details
Final metal content (post-sinter) 60.0–69.0% aluminum 6061
Filament density 1.20–1.50 g/cc
Diameter 1.75 mm (±0.05 mm)
Spool weight 0.5 kg
Sintering temperature ~600–650°C
Required nozzle 0.6 mm hardened steel
Linear shrinkage (post-sinter) ~15–20% in all dimensions
Hygroscopicity Less hygroscopic than PLA — do NOT dry
Origin Made in South Central Wisconsin, USA

Printing tips

  • Lighter than steel filaments — tolerates faster speeds
  • Filawarmer recommended for long prints
  • Direct drive preferred but Bowden works well with this filament
  • Scale models up 120–125% to compensate for sinter shrinkage

Common applications

  • Aerospace structural prototypes and brackets
  • Drone and RC component lightweighting
  • Bicycle and motorcycle hardware
  • Architectural cladding and fixtures
  • Heat sinks and thermal management
  • Anodised consumer products and prototypes

What you can make

Aluminum impeller printed and sintered
Aluminum impeller — sintered from FDM print
Aluminum impeller close-up
Real aluminum 6061 metal — printed on a desktop FDM

Frequently asked questions

Why is the metal content lower than other Filamets?

60–69% by weight is correct for aluminum — but aluminum’s low density means the volumetric metal content is comparable to copper or bronze. The finished sintered part is still ~95%+ aluminum by volume.

What kiln do I need for aluminum sintering?

Aluminum sinters at much lower temperatures (~600–650°C) than steel, so any kiln capable of ~700°C will work. The TVF FireX is overkill for aluminum; even an entry-level pottery kiln can handle it.

Can I anodise the finished part?

Yes — sintered 6061 anodises like cast or extruded 6061. You can also paint, polish or machine the finished part using standard aluminum workflows.

How does this compare to printing PLA?

Aluminum 6061 Filamet™ is the closest TVF metal to PLA in terms of print behaviour — light density, similar print temperatures, minimal warping. The complexity is entirely in the kiln stage.

What else you’ll need

TVF FireX Sintering Kiln

Comfortably handles aluminum sintering with headroom for steel and bronze later.

Filawarmer

Recommended for long prints. Reduces snap risk and resets spool memory.

Made in South Central Wisconsin, USA. World-class technical support provided for all TVF products.

(TVF-FILAMET-AL-175)

SKU TVF-FILAMET-AL-175
Brand The Virtual Foundry
Shipping Width 0.220m
Shipping Height 0.080m
Shipping Length 0.220m

Be The First To Review This Product!

Help other 3DPrintergear users shop smarter by writing reviews for products you have purchased.

Write a product review