Metal Additive Manufacturing, Vol. 11 No. 4 Winter 2025

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In addition to the latest industry news, this 176-page issue of Metal Additive Manufacturing magazine includes the following exclusive features:

NASA’s GRX-810: The story of an oxide-dispersion-strengthened superalloy designed for AM

In high-temperature propulsion applications, it is materials that set the boundaries of what is possible. Additive Manufacturing may have changed how we build components, but it hasn’t necessarily changed what extremes these components can endure in service.

NASA’s GRX-810 oxide-dispersion-strengthened superalloy tackles that constraint head-on: a high-temperature alloy designed, unlike legacy alloys, specifically for AM. Here, NASA’s Tim Smith and Paul Gradl explain how GRX-810 was developed, what has been demonstrated to date, and the pathway to commercial success.

EOS M4 ONYX: Exploring a customer-led path to scaling series metal Additive Manufacturing

Ahead of its Formnext launch, Metal AM was invited to EOS’s facilities near Munich, Germany, for an exclusive preview of the new EOS M4 ONYX and in-depth discussions with the developers, product managers, and senior leadership behind it. What emerges is a development story shaped by customer priorities: not a departure into record-breaking extremes, but a focused evolution designed to deliver what production users value most.

Dr Martin McMahon, Nick Williams, and Emma Lawn examine the technical priorities behind this response – process stability and repeatability, scan-field strategy, powder and waste handling, and the software controls supporting qualified series production.

Metal AM at the Vicenza Symposium: From Bulgari’s Cabochon ring to materials and process innovation

The inaugural Vicenza Symposium, which took place from September 2-4, 2025, brought jewellery manufacturers, researchers and industry leaders to Italy’s ‘Capital of Gold’ for three days of technical exchange in the UNESCO-listed Basilica Palladiana. Metal Additive Manufacturing featured prominently, from a striking Bulgari case study to research on hard-to-build precious metal alloys and emerging work on the Binder Jetting of gold.

In this report, Michela Ferraro presents insights from three selected presentations, based on in-depth conversations with the authors.

Dry-ice blasting for metal AM: toolcraft’s SupportBlaster approach to support removal for PBF-LB

As manufacturers push towards higher Additive Manufacturing throughput, the limitations of traditional support removal methods become increasingly visible. Manual practices cannot reliably meet the safety, repeatability, and cost targets required for industrial Laser Beam Powder Bed Fusion (PBF-LB).

toolcraft’s SupportBlaster 320-HA offers a semi-automated alternative, using dry-ice pellets to detach supports in a controlled manner. In this article, Joseph Kowen reviews the technology’s development, underlying process physics, and experimental data, highlighting its relevance for more scalable metal AM production.

PanOptimization’s PanX: Scalable simulation and optimisation for large-format metal AM

As metal Additive Manufacturing shifts toward larger, higher-value components, conventional AM simulation often fails to scale and remains focused on prediction rather than actionable process improvement. PanOptimization’s PanX seeks to address this gap with a scalable, high-fidelity Finite Element Analysis (FEA) solver for PBF-LB and DED that supports feed-forward optimisation of parameters, timing, and distortion compensation.

In this article, Erik Denlinger and Pan Michaleris examine the technical innovations enabling next-generation AM simulation and the commercial implications for throughput and yield, as well as market directions.

SMEs in focus: Denmark’s AM Summit 2025 targets industrial adoption and defence opportunities

Denmark’s AM Summit 2025, held on October 1, alongside the HI Tech & Industry Scandinavia Expo in Herning, offered a clear snapshot of the country’s fast-maturing AM scene. With a new format aimed at production-focused SMEs, the event drew many first-time attendees and sought to strengthen links between AM innovators and traditional manufacturers.

Across keynotes and panels, speakers explored the current shift from prototyping to manufacturing that delivers resilience and measurable value. Here, the Danish AM Hub’s Rikke Uldall-Ekman reports on event highlights.

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