The convergence of Additive Manufacturing and Artificial Intelligence: Envisioning a future that is closer than you think

The frenzy of media attention surrounding Artificial Intelligence (AI) dwarfs the past hype surrounding Additive Manufacturing (AM). Whether you look to the future with fear or excitement, there is no escaping the wave of change that is coming. Whilst we once again hear words like ‘revolution’ being used – to which so many have become immune – Dr Omar Fergani believes that we are now at a crucial point of convergence for AM and AI. Here, he explains why AM is in an especially strong position to leverage the potential of AI, with the power to transform many areas of our industry, from part design to machine operation, quality management and beyond. ... Read more »

Metal AM in the aerospace sector: from early successes to the transformation of an industry

December 18, 2023

Across the world, a new wave of aerospace engineers are designing and building the next generation of aero engines and systems around the revolutionary capabilities of Additive Manufacturing. Twenty years ago this was a vision, but today it is a reality. From fuel nozzles to Stage 5 and Stage 6 low pressure turbine (LPT) blades, housings to structural elements, in this article Metal AM magazine’s Technical Consultant Martin McMahon reviews the progress that has been made, shining a light on selected applications that offer insight to those in the aerospace industry who want to get up to speed with progress. ... Read more »

Hot Isostatic Pressing and AM: How to improve product quality and productivity for critical applications

September 15, 2023

Metal Additive Manufacturing is rapidly gaining momentum across a broad range of industries and is often used for producing components for challenging applications such as medical implants and rocket engines. To maximise the mechanical strength and fatigue resistance of such critical AM parts, they must be processed by Hot Isostatic Pressing (HIP) to eliminate any residual porosity, and heat treated. Jim Shipley from Quintus Technologies provides an overview of HIP and High Pressure Heat Treatment technology for Powder Bed Fusion AM and considers the opportunities that a new generation of HIP equipment presents. ... Read more »

Slowly but surely: Industrialising metal Additive Manufacturing the Norwegian way

September 15, 2023

While the Norwegian market for Additive Manufacturing has long revolved around prototyping and polymer materials, metal Additive Manufacturing has seen rapid development in recent years. This is in large part thanks to the opportunities that the country’s oil and gas industry is now seeing in the technology. In this article, Joppe N Christensen considers why it has taken so long to get started with metal AM in Norway and introduces companies and individuals who are now leading the way. ... Read more »

Exploiting your metal Additive Manufacturing data assets: Faster industrialisation and new revenue streams

September 15, 2023

While metal Additive Manufacturing is revolutionising industries from aerospace to healthcare, the need for efficient process development and the acquisition of validated material data is becoming increasingly important. In this context, a groundbreaking solution emerges – that of the platform-based exploitation of metal AM data assets to accelerate industrialisation and unlock new revenue streams. Here, Rosswag GmbH’s Philipp Schwarz and Gregor Graf delve into the significance of this concept and how it fits as a crucial piece in the AM industrialisation puzzle. ... Read more »

ADAXIS: On a mission to reduce the layers of complexity in robotic Additive Manufacturing

September 15, 2023

France’s ADAXIS is tackling two of the most complex advanced industrial manufacturing disciplines head on — Robotics and Additive Manufacturing. Its solution aims to make robotic Additive Manufacturing more accessible to any company that wants it, including for metal processes, irrespective of background or industry sector. Rachel Park spoke with Henri Bernard and Emil Johansson, two of ADAXIS’ co-founders, as well as project partners, to discover their story and ambitions. ... Read more »

International Conference on Electron Beam Additive Manufacturing: Highlights from EBAM 2023

July 14, 2023

Since the first conference on electron beam Additive Manufacturing in Nuremberg in 2016, the EBAM conference series has been the central meeting point for industry and academia to exchange knowledge on this dynamic area of AM. After the event was forced to go virtual in 2020 due to COVID-19, attendees were finally able to meet face-to-face again in Erlangen, March 22-24. Marie Franke-Jurisch and Dr Matthias Markl report on recent developments in materials, process, and machine technology, all of which serve to demonstrate that electron beam-based technologies are once again firmly established in the metal Additive Manufacturing world. ... Read more »

Metal AM on an industrial scale: GKN Additive draws on decades of sintering expertise to commercialise Binder Jetting

Binder Jetting’s position as an accepted mass production technology for precision metal components is on the near horizon. The coming success will, however, rely as much on expertise in the sintering process as it does on expertise in jetting binder onto a powder bed to make ‘green’ parts. This article reports on how GKN Powder Metallurgy’s Additive Manufacturing division, GKN Additive, has leveraged decades of sintering expertise in high-capacity continuous furnaces, combined with its application development expertise, to deliver the series production of special filters by Binder Jetting for Schneider Electric. ... Read more »

Volkmann: Making the case for the complete automation of powder handling in AM

Two worlds collide in Additive Manufacturing. Consider that a Laser Beam Powder Bed Fusion (PBF-LB) machine completes its job fully automatically over many hours. Yet, before and after that, a multitude of manual tasks often still need to be completed. Employees may be required to perform these tasks while wearing personal protective equipment (PPE) to protect themselves from metal dust, compounded by the high labour costs that this manual work incurs. Is this the future of cost-efficient, 24/7 production? Christian Mittmann and Manuel Henser, from Volkmann GmbH, believe that the real solution can be found in the complete automation of powder handling. ... Read more »

A stronger future, layer by layer: How next-generation software will drive adoption of metal AM

The growth of metal Additive Manufacturing has been held back, believes Oqton’s Dr Ben Schrauwen, by a specific set of challenges: repeatability, cost, and the need for a high level of expertise. This article considers how next-generation software solutions that leverage Artificial Intelligence, cloud computing, and hybrid modelling are improving metal AM workflows. By addressing all three challenges, Schrauwen believes that metal AM can achieve faster and deeper adoption, leading to a more efficient and innovative future. ... Read more »

Metal AM’s journey to industrialisation: Are we there yet? And what does the destination even look like?

July 13, 2023

Metal Additive Manufacturing is on a long journey, from the early technology concepts of several decades ago to its current usage in a relatively small number of markets with specific, highly-specialised application requirements. If the journey leads to the widespread adoption of metal AM technology by industry, can we ask, ‘Are we there yet?’ Dr Maximilian Munsch, Dr Eric Wycisk, and Matthias Schmidt-Lehr, from strategy consultancy and AM market analysis specialist AMPOWER, delve into the evolution, current status, and future prospects for the industry, seeking to uncover the true extent of its potential. ... Read more »

Adrian Keppler on Additive Manufacturing: An insider’s assessment from the outside

July 12, 2023

Dr Adrian Keppler has been an active participant in the AM industry for close on fifteen years. Based on his past experience as the Managing Director, and later CEO, of EOS GmbH, and his current role on the advisory boards of numerous AM startups, Keppler believes that more can, and should, be done to advance industrial applications of AM. Are the industry’s efforts to develop new technologies without perfecting and industrialising existing technologies holding it back? Should the less exciting work of industrialisation be prioritised over the next shiny technology release? Joseph Kowen interviews Keppler for Metal AM magazine. ... Read more »

In the latest issue of Metal AM magazine

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Extensive AM industry news coverage, as well as the following exclusive deep-dive articles:

  • The GRCop story: The development, production and Additive Manufacturing of NASA’s rocket engine alloys
  • Formnext 2023: Innovations in metal Additive Manufacturing from the industry’s leading international exhibition
  • Cybersecurity in Additive Manufacturing: Securing the industry’s future
  • Additive Manufacturing in the jewellery industry: exploring the potential of platinum and titanium
  • Mission possible: The five-year plan to gain FAA and EASA acceptance of in-process monitoring

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