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Whether a weld is hard or not has a lot to do with it's chemistry. Run of the mill off the shelf fabrication wire shouldn't be anything any machine shop worthy of the title couldn't handle in an as-welded state. Most of that stuff barely registers on the rockwell chart. Once you start adding alloys ...

No dog in this fight, and little experience in the 3d print world, as envisioned here anyway, but 3D metal printing has been doable for at least the last 2 decades. So far the only thing it really lacks is any practical application. Until someone comes up with a way to do it A) accurately so the ...