Metal Additive Manufacturing, Vol. 10 No. 1 Spring 2024

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In addition to the latest industry news, this 204-page issue of Metal Additive Manufacturing magazine includes the following exclusive features:

Metal powders in Additive Manufacturing: An exploration of sustainable production, usage and recycling

Sustainability has risen to the top of the global manufacturing agenda. Whilst metal AM has long been considered a green technology because of its net-shape capabilities, it is far from being a process absent of environmental impact.

Here, Martin McMahon explores how global efforts are being made to improve this through the use of more sustainable metal powders, combined with a greater focus on powder reuse and recycling. Inextricably linked to this are, of course, economic gains and, in terms of supply chain, national security benefits.

Inside Wayland Additive: How innovation in electron beam PBF is opening new markets for AM

UK-based Wayland Additive is convinced that, when it comes to metal Additive Manufacturing, Electron Beam Powder Bed Fusion (PBF-EB) has a bright future ahead. Whilst laser-based PBF is the most widely commercialised AM technology, it has inherent limitations that electron beam-based innovations such as Wayland’s NeuBeam process promise to overcome.

Rachel Park reports on how the technology could open up the AM market by enabling users of the Calibur3 machine to rapidly develop and commercialise a wider range of industrial materials.

An end-to-end production case study: Leveraging data-driven machine learning and autonomous process control in AM

For Additive Manufacturing to mature as an industrial production process, believe Tommaso Tamarozzi (Oqton) and Juan Carlos Flores (Baker Hughes), it needs to be faster, simpler, and more reliable. This article reports on a step toward this goal through the development of an end-to-end AM workflow for the serial production of a Variable Resistance Trim (VRT) component.

Built on a fully digital framework, it includes simulation, real-time process monitoring, anomaly analysis, and data preparation automation, thus laying the foundation for an AM workflow that delivers consistent quality and the documentation necessary for certification.

Consolidation, competition, and the cost of certification: Insight from New York’s AM Strategies 2024

Additive Manufacturing conferences rarely attract as many industry CEOs as New York’s Additive Manufacturing Strategies event, let alone persuade them to share the stage for panel discussions.

AMS2024 was no exception. On the back of a turbulent financial year for many of the industry’s leading companies, how do those very CEOs see the state of the industry now, and what do they see as the biggest challenges ahead? Rachael Dalton-Taggart reports for Metal AM magazine.

Scandium’s impact on the Additive Manufacturing of aluminium alloys

The future of Additive Manufacturing lies in part production at scale. Innovation must, therefore, focus on how to reduce part cost and improve performance. Unlike other manufacturing processes, weight is time in AM – and time is money; raw material costs take a back seat when it comes to overall part cost.

Here, Jonathan Meyer (APWORKS) and John Barnes (Metal Powder Works/The Barnes Global Advisors) explore the case for scandium-based aluminium alloys for AM from both technical and economic perspectives.

AM for medical implants: An analysis of the impact of powder reuse in Powder Bed Fusion

The growing use of titanium Additive Manufacturing for the production of medical implants is a major success story for the industry. With this growth, however, come vast volumes of process data which need to be monitored to ensure compliance with tight regulatory requirements.

Here, Peter Lindecke, amsight GmbH, explains how holistic analysis software can be used to monitor the impact of powder reuse strategies in Electron Beam Powder Fusion to ensure the best possible outcomes.

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