It was clear at SHOT Show 2025 that additive manufacturing in the suppressor market was on the rise. The industry has been a clear frontrunner in the adoption of additive manufacturing as a production process. As firearm suppressor technology advances, manufacturers are constantly seeking new ways to improve performance, reduce weight, and enhance production efficiency. FreeFORM Technologies was founded on the basic principle that more additive manufactured components needed to get into the hands of consumers or companies to increase adoption. There was a gap in the market – you could buy a printer, but there were almost zero contract manufacturers offering Metal Binder Jet as a service. Enter FreeFORM Technologies – one of the first Metal Binder Jet contract manufacturers in the world. With over 20 machines and a desire to support the firearms industry, FreeFORM began working with customers on what their pain points were with additive manufacturing and how we could overcome those barriers with Metal Binder Jet.

One of the most significant breakthroughs was in suppressor manufacturing and the adoption of Metal Binder Jet (MBJ) technology, which offers key advantages over traditional Laser Powder Bed Fusion (LPBF) methods. While LPBF has been widely used in additive manufacturing, it presents challenges such as residual stress buildup, high production costs, and limitations in scalability. Additionally, printing a full suppressor tube using LPBF is costly and inefficient. Metal Binder Jet technology overcomes these challenges by providing a more efficient and cost-effective solution, particularly when used to create a complex internal core that fits within a traditionally manufactured tube.

Key Advantages of Metal Binder Jet Technology for Suppressors:

1. Increased Design Freedom – MBJ allows for the creation of intricate, high-performance baffle structures without the support structures required in LPBF, enabling more efficient suppressor designs.

1. Higher Production Efficiency – Unlike LPBF, which relies on a layer-by-layer laser sintering process, MBJ prints components rapidly using a binder-based approach before undergoing sintering, significantly reducing production time.

1. Reduced Residual Stress and Distortion – LPBF exposes metal powder to high-energy lasers, creating residual stresses that often require post-processing. MBJ minimizes these stresses, leading to improved mechanical properties and reduced risk of warping.

1. Cost-Effectiveness and Scalability – MBJ eliminates the need for expensive laser systems and can produce multiple parts simultaneously, reducing per-unit costs and making large-scale production more viable. Furthermore, by focusing MBJ on the internal core while using traditional manufacturing methods for the outer tube, manufacturers can significantly reduce costs while maintaining high performance and aesthetics.

1. Enhanced Material Properties – MBJ produces dense, high-strength metal components with properties comparable to wrought materials, ensuring durability and reliability in demanding applications. Common materials used in MBJ for suppressor manufacturing include 17-4PH Stainless Steel, Inconel 625, and Inconel 718, which offer excellent strength, corrosion resistance, and high-temperature performance. Additionally, these materials are weldable and machinable, allowing for seamless integration with traditionally manufactured components and further expanding design possibilities.

As the firearms industry continues to innovate, Metal Binder Jet technology is poised to reshape the suppressor manufacturing landscape by enabling lightweight, high-performance designs at lower costs. With its ability to streamline production while enhancing product performance, MBJ represents the next evolution in firearm suppressor technology.

For more information about Metal Binder Jet technology and its applications in suppressor manufacturing or other firearms component needs, please contact FreeFORM Technologies at 814-834-7927 or sales@freeformtech.com.