Sennheiser turns to Additive Manufacturing for its IE 600 earphones

March 8, 2022

Sennheiser has utilised Additive Manufacturing in the production of its IE 600 earphone (Courtesy Sennheiser)

The newly released IE 600 earphones from Sennheiser electronic GmbH & Co KG, Wedemark, Germany, feature housings produced by metal Additive Manufacturing. The purpose of the metal AM housings, which are hand-finished for aesthetics, is to protect the delicate transducer and thus extend the product’s lifespan.

The housings, manufactured by Heraeus AMLOY Technologies GmbH on a TruPrint 2000 Laser Beam Powder Bed Fusion (PBF-LB) Additive Manufacturing machine from Trumpf, are built from Heraeus’s Amloy ZR01. This amorphous zirconium alloy was selected by Sennheiser for its durability – it’s reputedly tougher than high-performance steel – in combination with its aesthetic surface quality.

“Working at the cutting edge of technology is super exciting and knowing that we work on the same materials as the most demanding organisations in the world use – like NASA – is an extremely exciting opportunity,” stated Jermo Köhnke, Product Manager at Sennheiser. “It always makes your heart jump if you’re an engineer – or just a tech fan.”

The additively manufactured casings for the IE 600 earphones (Courtesy Sennheiser)

Heraeus Amloy ZR01 is said to have triple the hardness and flexural strength of high-performance steel. Shock-frozen during manufacturing, amorphous metals never have a chance to form a crystalline structure like conventional metals. The additively manufactured chambers and channels require no milling after production. Post-processing operations include steel shot blasting, polishing and surface treatment, resulting in an extremely durable and wear-resistant component. Previously, this advanced material was trialled by NASA for ice cutting on one of Jupiter’s moons.

Jürgen Wachter commented, “Amorphous alloys are an extraordinary new class of materials. Our high-tech AMLOY ZR01 is used in components for aerospace and MedTech applications that require ultra-high precision and robustness. We are proud that Sennheiser evaluated our space-grade amorphous alloy and decided to use it for the IE 600.”

The IE 600 earphones are now available for purchase.

In the latest issue of Metal AM magazine

Download PDF

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

  • What happens when you take the powder out of AM? Charting the rise of wire-based DED with WAAM3D
  • Smart sensor-integrated parts by AM: A look at a novel possibility with industrial applications
  • Tailored materials for AM: How a 'powder kit' can achieve greater material diversity with fewer resources in PBF-LB
  • QuesTek's ICMD: Faster, cheaper, and better alloy development for Additive Manufacturing
  • NanoAL: Alloy development on an open parameter PBF-LB machine, from installation through to Rapid Alloy Screening
  • Using the Six Sigma method to optimise metal powder spreading in PBF-LB
  • Insights from R&D to part production: How CT analysis can advance metal Binder Jetting
  • Corrosion and wear resistence of materials processed by beam-based AM technologies

The world of metal AM to your inbox

Don't miss any new issue of Metal AM magazine, and get the latest industry news. Sign up to our twice weekly newsletter.

Sign up

News from the industry…

    News from the industry…

    Discover our magazine archive…

    The free to access Metal Additive Manufacturing magazine archive offers unparalleled insight into the world of metal Additive Manufacturing from a commercial and technological perspective through:

    • Reports on visits to leading metal AM part manufacturers and industry suppliers
    • Articles on technology and application trends
    • Information on materials developments
    • Reviews of key technical presentations from the international conference circuit
    • International industry news

    All past issues are available to download as free PDFs or view in your browser.

    Browse the archive

    Looking for AM machines, metal powders or part manufacturing services?

    Discover suppliers of these and more in our comprehensive advertisers’ index and buyer’s guide, available in the back of Metal AM magazine.

    • AM machines
    • Process monitoring & calibration
    • Heat treatment & sintering
    • HIP systems & services
    • Pre- & post-processing technology
    • Powders, powder production and analysis
    • Part manufacturers
    • Consulting, training & market data
    Download PDF
    Share via
    Copy link
    Powered by Social Snap