3D Systems expands materials range with Scalmalloy and M789

September 2, 2021

Suspension rocker produced in Certified Scalmalloy (A) on 3D Systems DMP Flex 350 metal AM machine (Courtesy 3D Systems)

3D Systems, Rock Hill, South Carolina, USA, reports that it has added Certified Scalmalloy (A) and Certified M789 (A) to its materials portfolio in order to facilitate demanding industrial high-strength, corrosion-resistant parts for Additive Manufacturing applications in sectors such as aerospace, motorsports & automotive, semiconductor, energy, and mould making.

This addition will enable the use of the materials on 3D Systems’ Direct Metal Printing (DMP) platform (a Laser Beam Powder Bed Fusion (PBF-LB) based process). The company states that it has worked with the material manufacturers APWORKS and voestalpine Böhler Edelstahl to certify the materials and customers are now able to work with the company’s Application Innovation Group (AIG) to certify these materials for use with its DMP Flex 350 and DMP Factory 350 AM machines.


Scalmalloy is a high-strength aluminium alloy that has a tensile strength of 520 MPa and yield strength of 480 MPa, significantly stronger than the reference material AlSi10Mg. The high strength is said to make it ideal for additively manufacturing weight-efficient, load-bearing components.

Ideal applications in the aerospace sector include passive RF components (such as filters, waveguides, etc.) and lightweight structural components. In the motorsports and automotive sector, applications include metal structural components (suspension brackets, transmission casings), energy and fluid management. In the semiconductor market, components include fluid flow systems (manifolds) and thermal management (such as cooling nozzles and wafer tables).

Parts produced using Scalmalloy can be chemically cleaned during post-processing which removes surface residue to deliver a final part with optimal surface finish.

“Adding the capability to additively manufactured parts from Scalmalloy to our portfolio is an important step forward; especially for our aerospace customers,” stated Dr Michael Shepard, vice president, aerospace & defense segment, 3D Systems. “Scalmalloy has a very attractive strength-to-weight ratio and is more amenable to 3D printing than many conventional high-strength aluminium alloys. These performance attributes make it ideal for aerospace applications and we are excited to see how our customers will use 3D printed Scalmalloy components to continue to push the envelope with their innovation.”

A high-strength mould insert for air vents produced with metal AM in Certified M789 (A) cobalt-free tool steel (Courtesy 3D Systems)


M789 allows 3D Systems’ customers to produce high-strength moulds and tooling that can not only be hardened up to 52 HRC, but are also free of Cobalt. The company has attained certification of M789 for its DMP platform through collaboration with its partner GF Machining Solutions, addressing customers’ requests for hard, corrosion-resistant tooling steel for advanced applications.

The resulting parts are ideal for long-term use, able to withstand both the rigours of repetitive manufacturing processes as well as use in regions with high humidity. Ideal applications for this material include mould inserts with conformal cooling, drill bits and cutting tools, as well as automotive tyre moulds, drive train parts and axle components.

Kevin Baughey, Segment Leader, transportation & motorsports, 3D Systems, commented, “Our customers in the automotive industry are increasingly relying on Additive Manufacturing to advance and accelerate their innovation. Having M789 as part of our metal 3D printing solution delivers greater accuracy to our automotive customers. This is enabling them to use the technology for applications that require higher fidelity and thinner walls, like die inserts with conformal cooling and tire tread moulds, and providing them a competitive advantage.”


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