Applications

Metal Additive Manufacturing and the new Space Race: The inside track with Launcher and AMCM

In October 2020, New York City-based space technology company Launcher started testing its full-sized E-2 liquid rocket engine, designed to deliver the highest performance at the lowest cost for smaller space launch vehicles. That the E-2 features a one metre tall single-piece copper alloy Laser Beam Powder Bed Fusion (PBF-LB) combustion chamber is remarkable. What is even more impressive is the fact that Launcher, a company with less than twenty employees, achieved this in a short time frame and to a relatively modest budget. Metal AM magazine’s Nick Williams reports on the project and Launcher’s close collaboration with specialist PBF-LB machine builder AMCM GmbH. [First published in Metal AM Vol. 6 No. 4, Winter 2020] ... Read more »

Metal AM in South Africa: Research and commercial initiatives bring the benefit of AM to the African continent

The Additive Manufacturing industry in South Africa has come a long way since the installation of the country’s first AM machine in 1991, with a number of research and commercial initiatives driving the development of world-class applications and knowledge. In this article, Terry Wohlers and Olaf Diegel, Wohlers Associates, present an overview of metal Additive Manufacturing activities in South Africa, from the technology’s life-changing use for medical implants to its development for rapid, large-scale part production and beyond. [First published in Metal AM Vol. 6 No. 4, Winter 2020] ... Read more »

Metal Additive Manufacturing in New Zealand: An overview of research, commercial activities and strategic initiatives

For a country with a total population significantly smaller than that of cities such as London or New York, New Zealand is ‘punching above its weight’ when it comes to developing expertise in Additive Manufacturing and educating design engineers in how to use it. Olaf Diegel, a professor at New Zealand’s University of Auckland and associate consultant at Wohlers Associates, and Terry Wohlers, president of Wohlers Associates, report on AM activities and highlight a novel range of successful commercial applications. [First published in Metal AM Vol. 6 No. 3, Autumn/Fall 2020] ... Read more »

From aerospace engineering to AM: Melanie Lang on FormAlloy and the future of Directed Energy Deposition (DED)

When you mix a childhood obsession with rockets and space travel, a career at some of the biggest global names in aerospace, and a curiosity about hobbyist 3D printing developed through maker fairs, it was inevitable that FormAlloy’s Melanie Lang would end up in the world of metal Additive Manufacturing. Metal AM magazine’s Emily-Jo Hopson-VandenBos interviewed Lang, CEO and co-founder of Directed Energy Deposition (DED) specialist FormAlloy, about her route into AM, her company’s technology and the outlook for the process. [First published in Metal AM Vol. 6 No. 3, Autumn/Fall 2020] ... Read more »

Advancing rocket propulsion through Additive Manufacturing, novel surface finishing technologies and public-private partnerships

Whilst Additive Manufacturing is undoubtedly having a huge impact on the design and manufacture of rocket propulsion systems, most notably combustion chambers and nozzles, the Achilles’ heel of most AM processes is as-built surface finish. Whilst in many AM applications surface finish may be largely irrelevant to a component’s function or performance, when it comes to high-cycle fatigue properties, achieving the required level of smoothness is critical to performance. In this article, Justin Michaud, REM Surface Engineering, reports on advancements achieved in this area through a public-private partnership with NASA. [First published in Metal AM Vol. 6 No. 3, Autumn/Fall 2020] ... Read more »

Atherton Bikes: The journey from world title success to mastering Additive Manufacturing for performance bike production

The story of Atherton Bikes stands out as a shining example of how metal Additive Manufacturing can be successfully embraced and commercialised by a small, dedicated team of people. In the case of the Atherton family, the technology has not only enabled them to maximise their performance at the pinnacle of professional mountain biking, but has also opened a path to commercial bike production in an industry where frame manufacturing is dominated by Taiwan and China. In an article that will appeal to anyone considering the use of metal AM, the Atherton Bikes team shares its experiences with Robin Weston. [First published in Metal AM Vol. 6 No. 3, Autumn/Fall 2020] ... Read more »

In pursuit of perfection: A case study on how Bugatti and APWORKS leverage the full potential of AM

It is far too easy to overuse superlatives when speaking about hypercars or Additive Manufacturing. When the discussion combines both – Bugatti’s new driver-focused Chiron Pur Sport and a high-performance AM component that truly pushes today’s processes to their limits – the result is worthy of a closer look. In the following in-depth case study, Bugatti and APWORKS explain the requirements, development and production of the Chiron Pur Sport’s exhaust finisher and share insight into some of its hidden details, from lattice structures to nature-inspired honeycomb reinforcements. [First published in Metal AM Vol. 6 No. 2, Summer 2020] ... Read more »

Innovation and differentiation: Precious metal Additive Manufacturing in the jewellery sector

Rich in creativity and rooted in a long artisanal manufacturing heritage, one would imagine that there can be few sectors as perfectly suited to embrace the potential of metal Additive Manufacturing than the jewellery industry. In reality, however, the sector continues to hold back on the full-scale adoption of AM, despite numerous successes. In this article, Michela Ferraro-Cuda considers progress to date in the adoption of precious metal AM in the jewellery industry, and showcases a number of leading designers who have leveraged the technology’s potential for innovation and differentiation. [First published in Metal AM Vol. 6 No. 2, Summer 2020] ... Read more »

Managing the industrialisation process: Notes from Euro PM’s seminar on the future of Additive Manufacturing

During the Euro PM2019 Congress and Exhibition in Maastricht, the Netherlands, this October, a number of Special Interest Seminars were held focusing on various aspects of the Powder Metallurgy and Additive Manufacturing industries. In one seminar, Dr Uemit Aydin, GKN Additive, and Nicholas Turner, Materials Solutions, looked to the future of Additive Manufacturing and expressed their views on its industrialisation. David Whittaker attended the SIS on behalf of Metal AM magazine and reports on its conclusions.[First published in Metal AM Vol. 5 No. 4, Winter 2019] ... Read more »

From lightweighting and material efficiency to energy consumption: Where are we on AM’s sustainability journey?

Additive Manufacturing has been heralded as a game-changing technology of the future. But while many ‘green’ and ecological initiatives have bloomed from the AM movement, the question remains: “Is AM environmentally friendly?” As Olaf Diegel, Ray Huff, and Terry Wohlers explain, the short answer is: it can be, in the hands of good designers and well-informed manufacturers. As with any tool or process, knowledge and experience are key. It is important to explore the many ways AM is applied in sustainable ways and whether it is improving. [First published in Metal AM Vol. 6 No. 1, Spring 2020] ... Read more »

Download the latest issue of Metal AM magazine

Our latest issue is now available to view online or download in PDF format.

As well as an extensive AM industry news section, this 204-page issue includes articles and reports on:

  • Optimised thermal management in semiconductor fabrication using AI-enabled generative design and Additive Manufacturing
  • Forging a process for mass customisation via metal Additive Manufacturing
  • Bringing it all together: How Materialise is integrating manufacturing and software expertise to shape AM’s future
  • Pedal to the metal at the Digital Manufacturing Centre: Redefining what’s possible for AM in hypercars and beyond
  • The future is Additive Manufacturing – if we take a more holistic view of the design opportunities
  • Building a case for radical collaboration plus quality standards: The pathway to growing the AM industry
  • Distributed manufacturing: Old concept, new relevance, new technology?
  • Design for Additive Manufacturing: A workflow for a metal AM heat exchanger using nTopology (BJT)
  • Taking the holistic view:
    Defining the state-of-the-art in the evolving PBF-LB machine marketplace
  • > More information

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