Additive Manufacturing, a game-changing technology: Key projects in 2022

Metal 3D printing, more formally known as Metal Additive Manufacturing, can produce seamless designs by applying a diverse set of raw materials. The most commonly used element among them is aluminium. Detailed components and intricate designs, which were not even imaginable in the era gone by, are now being generated in an instant by high-end Additive Manufacturing devices. Just a few years back, the process was only used for producing technological prototypes, but now it is being hailed as one of the most compact yet swift methods to acquire the specific configurations of an object. Industries, including automobile, aerospace and pharmaceutical, are all embracing this revolutionary technology as it is much more cost-effective and hassle-free.

Additive Manufacturing (AM) follows a method wherein it produces three-dimensional components putting layer over layer of the same material, which can either be polymer or metal-derived. With the surge in demand for Electric Vehicles (EVs) worldwide, the need to manufacture precisely engineered car parts is increasing each day, and the most commonly used material in this sector is aluminium for its lightweight property. But to achieve perfection and stability, aluminium needs to be amalgamated with other metals to form an alloy durable enough for the manufacturing process. One such aluminium alloy is AlSi10Mg, which is a combination of silicon, magnesium and aluminium, usually transformed into raw material from powder by Selective Laser Melting (SLM) technology. Thus, Powder Metallurgy and Additive Manufacturing are synonymous with one another, and the development of one is not possible without the other. One needs to fill in the three-dimensional digital illustrations that accurately replicate the components' desired shape into the machine for a smooth delivery of pre-determined parts. The entire process is much more efficient and quick than the conventional methods of die-casting or injection moulding since the final product is flawless.

Some of the top innovators in the Additive Manufacturing sector in 2022 are:

AML3D: Australian leader of AM technology, AML3D combines the intense knowledge of welding science, materials engineering, robotics automation and proprietary software to generate an automated 3D system compatible with their flagship Wire Additive Manufacturing (WAM®) process. This is where an alloyed wire is sent through the nozzle of an AM device while being heated simultaneously to form cost-effective casted solutions. The company's name is so greatly regarded that American aeroplane maker Boeing is one of its esteemed customers. In July this year, AML3D received an order worth US$140,000 to manufacture high-strength aluminium components and structural items, also termed as 'fly' parts, for the American aviation industry leader, Boeing.

SLM Solutions: Hailing from Germany, SLM Solutions is a provider of metal-based additive manufacturing systems and recently has collaborated with Elementum 3D, an AM powder developer, to create premium aluminium alloys 2024 and 6061 or aerospace grade 7050 and 7075 by 2023. The latest SLM NXG XII 600 machine acquired by Elementum will help the company to generate an aluminium alloy suitable for additive manufacturing. The partnership may give rise to exceptional raw materials as Elementum will use its powder-making knowledge while SLM will lend its expertise to perfecting the AM device. Also, in August 2022, Bosch installed two SLM®500 machines to produce AlSi10Mg aluminium components with increased precision.

Gränges Powder Metallurgy: A subsidiary of Swedish aluminium solutions provider, Gränges AB has earned its name worldwide with the introduction of the Dispal® series, a range of high-performance spray-mended aluminium materials specialised for the AM industry. In November 2022, they added a new discovery to the Dispal® portfolio, which already has five different aluminium alloys attributed to its name. The new aluminium alloy, S260 AM, has a lower thermal expansion rate than the other mixtures in the portfolio. The S260 AM is suitable for components that need to be machined for very tight tolerances. It has an excellent performance quotient in diverse weather conditions where it might encounter major temperature discrepancies (e.g., oil pump gears).

Equispheres: An Ottawa-based materials science company Equispheres has mastered the art of producing high-quality raw materials to be used in the Additive Manufacturing sector. The organisation is continuously developing more efficient materials for use in making precisely engineered components for the automobile and other critical industries. Recently, it has come up with NExP-1, a variant of the AlSi10Mg alloy, which is a non-explosive material and is also non-combustible. This particular innovation will considerably benefit the AM industry since it reduces the risk factor by one hundred per cent. Also, not many days back, Equispheres partnered with Morf3D to discover new high-performance aluminium powders that may augment the performance and productivity of the metal additive manufacturing (AM) sector.

AM 4 AM: Advanced Materials for Additive Manufacturing (AM 4 AM), a company based in Luxembourg, is gaining international importance in the context of AM for its incredible research on developing new endurable materials for printing processes. In October, it launched its patented aluminium alloy powder called HiPerAl, which earned very fast recognition in the component manufacturing market. Soon, this led the company to form an alliance with French R&D organisation Pint vouching for the latter's expertise to create HiPerAl prototypes or mechanical test components for future mass production.

NanoAL LLC: The enterprise was formed after rigorous research over 17 years at Northwestern University, Illinois, and since its inception, has been widely engrossed in perfecting aluminium alloys for use in the AM industry. The firm's primary product was a creep-resistant aluminium alloy for electrical wire bonding applications, which later was followed by the initiation of the Addalloy® family of powdered aluminium alloys designated solely for 3D printing jobs. NanoAL has a rigid grip over the USA's defense, maritime and automobile sectors, generating huge orders from each department. As early as June 2022, NanoAL signed a three-way Joint development agreement with Mitsubishi Corporation RtM Japan Ltd. (RtMJ) and Nikkei MC Aluminium Co., Ltd. (NMA) to produce and market enhanced high-pressure die-casting aluminium alloys for the automobile and consumer electronics market. The cooperation was preceded by NanoAL's licencing agreement with Japan's Mitsubishi in February 2021. These steps are significant for the materials development company as they solidify its position in the international AM market, especially in the Asian sector.