Emerging Technology with Metal Additive Manufacturing

Additive manufacturing (AM), commonly known as 3D printing, has experienced explosive growth in recent years. While initially used primarily for rapid prototyping of plastic parts, AM is now being widely adopted for production of functional metal components. Metals that can be 3D printed include stainless steel, titanium, nickel alloys, aluminum and copper alloys. Compared to traditional subtractive manufacturing methods, AM offers new design possibilities and advantages for the production of complex metal parts.

Metal Additive Manufacturing Processes

There are three main Metal Additive Manufacturing processes in use today: powder bed fusion, directed energy deposition, and binder jetting. Powder bed fusion systems mimic traditional 'layered manufacturing' by selectively fusing metal powder particles using a laser or electron beam. The most common systems are selective laser melting (SLM) and electron beam melting (EBM). In directed energy deposition, a laser or electron beam directs energy to fuse powder materials as they are deposited, allowing parts to be built outside of an enclosure. Binder jetting uses inkjet print head technology to deposit a liquid binding agent onto layers of powder, solidifying the final part through post-processing.

Benefits for Complex Parts production

Benefits of Metal Additive Manufacturing enables the economic production of complex parts that would be difficult or impossible to manufacture using conventional methods. Complex internal channels, optimized lattice structures and integrated features can all be built within a single part. This has significant benefits across various industries:

- Aerospace: Weight reduction through topology optimization helps lower fuel costs. AM allows embedded features like cooling channels in jet engine components.

- Medical: Implants can be better customized for individual patient anatomy. 3D printed orthopedic implants have complex porous structures that promote bone in-growth.

- Automotive: Conformal cooling channels improve mold performance. AM enables net-shape production of parts with less assembly.

- Energy: Turbine blades with lattice structures can withstand higher temperatures and pressures. AM facilitates single-piece constructions.

New Design Opportunities

Metal AM opens up entirely new possibilities for part and system design. Engineers can leverage topology optimization to remove non-critical material from designs without compromising strength or function. Internal structures like microlattices create tunable stiffness or customize heat/fluid transfer characteristics. Consolidation of multiple components into one 3D printed part reduces assembly time and costs. Designs can now take full advantage of digital blueprints without the limitations of traditional manufacturing constraints.

Production Scaling and Quality

While metal AM has made significant advances, further improvements are still needed for many production applications. Build speeds, part sizes and material options are increasing regularly as technology progresses. However, scaling AM from prototypes to mass production remains challenging due to long processing times and high equipment/material costs compared to conventional manufacturing. Quality assurance, consistency and repeatability are other ongoing focus areas. Establishing robust process control, standardization and certification will be important for qualifying AM parts in safety-critical applications.

Additive’s Impact on Global Supply Chains

The potential of distributed manufacturing using metal 3D printers will massively disrupt traditional supply chains. Instead of centralized production facilities, localized ‘microfactories’ equipped with AM machines can manufacture parts on-demand, reducing transportation needs and inventory carrying costs. Spare parts can be printed at repair depots when and where needed, minimizing downtime. Global manufacturers are evaluating ‘on-shoring’ production back to domestic markets using AM to counter trade tariffs and challenges with overseas outsourcing. This transition will redefine supply chain logistics for the 21st century.

Advances in metal 3D printing processes, materials and post-processing are enabling broader use across more industries. Applications are shifting from prototypes and low-volume production to medium-to-high volume end-use parts. Government and industry R&D investment are accelerating the scaling and qualification of additive manufacturing technologies. By 2030, metal AM is projected to capture over 25% of the $10+ billion spending on 3D printed metals. Widespread industrial adoption will depend on demonstrating robust and repeatable processes for safety-critical usage. With continued innovation, additive manufacturing is poised to transform global manufacturing by enabling previously impossible designs with supply chain flexibility.

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