Design for AM

How metal Additive Manufacturing is transforming modern hydraulic systems

Hydraulic systems are important across many industries, providing high power density in compact, efficient packages. However, conventional subtractive manufacturing methods restrict design and performance. Additive Manufacturing offers a solution, enabling the production of complex geometries that enhance flow dynamics whilst minimising material use. In this article, Valeria Tirelli, CEO of Aidro Srl, considers how AM is reshaping hydraulic component design and production, offering new possibilities for enhanced performance, sustainability, and application-specific customisation. ... Read more »

High-performance product development in the era of computational design: A case study with nTop and NASA

The era of computational design is reshaping the engineering and product development landscape, enabling industries to tackle complex design challenges with unprecedented speed and efficiency. This article explores how NASA, using software from nTop, leveraged cutting-edge tools and methodologies in a unique application development. In combination with the capabilities of Additive Manufacturing, the project saw a scientific instrument component’s original material, beryllium, replaced with an aluminium alloy, providing a significant part cost reduction whilst exceeding all necessary performance requirements. ... Read more »

The Additive Manufacturing of record-breaking pure copper heatsinks for high-performance computing applications

As high-performance computing (HPC) and Artificial Intelligence (AI) applications drive demand for more powerful processors, thermal management has become a critical challenge. This article explores the development of a generatively-designed and additively manufactured liquid nitrogen (LN2) heatsink, created by 3D Systems and Diabatix in collaboration with SkatterBencher and ElmorLabs, that achieves groundbreaking cooling performance. Thanks to Additive Manufacturing, the resulting pure copper heatsink promises to open up new markets for the technology in this rapidly growing market. ... Read more »

Fly-by-wire: How Additive Manufacturing took to the skies with Norsk Titanium

With seven structural titanium parts flying on every Boeing 787 Dreamliner, a Master Supply Agreement with Airbus for the A350, and projects with the likes of Northrop Grumman and General Atomics, Norsk Titanium is setting the pace when it comes to the production of airframe components by Additive Manufacturing. By using wire instead of powder and its own proprietary version of the Directed Energy Deposition (DED) process, the company combines high deposition rates with aerospace-grade materials properties. Martin McMahon visited the company on behalf of Metal AM magazine. ... Read more »

Award-winning metal AM parts from the MPIF’s 2024 Design Excellence Awards

For many decades, North America’s Metal Powder Industries Federation (MPIF) has organised its PM Design Excellence Awards competition in order to showcase the capabilities of the Powder Metallurgy industry. With the growing commercial success of metal powder-based Additive Manufacturing, the competition is seeing an ever larger number of entrants from this sector. Award-winning parts in this year’s competition include parts not only produced by Laser Beam Powder Bed Fusion, but also a wide range of innovative sinter-based AM processes. ... Read more »

Enhancing the productivity of Additive Manufacturing facilities through PBF-LB automation

The metal Additive Manufacturing industry has significantly increased machine productivity in recent years. In the case of Laser Beam Powder Bed Fusion (PBF-LB), efforts have primarily focused on what happens inside the build chamber. Here, Sebastian Becker, Head of Product Management Metal, EOS GmbH, reports on how, with Grenzebach Maschinenbau GmbH and Volkmann GmbH, the company is looking outside of the build chamber. Thanks to automation, machine time utilisation can be taken from an estimated 60% to nearer 90% through rapid automated build box exchange and fully automated powder removal and recycling. ... Read more »

BMW Group: Laying the foundations for the application of metal Additive Manufacturing in the automotive industry

The very existence of BMW Group’s state-of-the-art Additive Manufacturing Campus, located close to Munich, speaks volumes about the potential of AM technology in the automotive industry. In April, Metal AM magazine’s Technical Consultant, Martin McMahon, and Managing Editor, Nick Williams, had the opportunity to visit the campus. As is revealed here, they discovered an operation that not only functions as an application development centre and centralised location for the BMW Group’s AM expertise, but also operates as a model AM factory built around the concepts of productivity and automation. ... Read more »

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 »

Cybersecurity in Additive Manufacturing: Securing the industry’s future

In the digital world of Additive Manufacturing, just how cybersecure are your operations and your customers’ critical parts? A survey of AM producers has suggested that the answer is probably not secure enough. In this article, Auburn University’s Prof Mark Yampolskiy, and industry analyst Joseph Kowen, present a high-altitude overview of the security threats facing those in the AM community. Cybersecurity, they suggest, should be considered as no less important than metallurgy or ‘Design for AM’ and, with the development of AM-specific standards and third-party security solutions, it need not be an overwhelming task. ... 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 »

Case study: The development of a multi-material heat sink by Additive Manufacturing using Aerosint technology

Additive Manufacturing offers the opportunity to transform industrial production. Currently, however, AM components are typically produced in only one material, which in many cases does not allow for full performance utilisation. In this article, Xiaoshuang Li and Arthur Seibel describe, through a heat sink case study, how multi-material design and manufacturing can increase component performance as well as integrate additional functionalities when using the Laser Beam Powder Bed Fusion (PBF-LB) process. ... Read more »

Additive Manufacturing for jewellery and watchmaking: Exploring the potential of sinter-based technologies

Three years ago, Metal AM magazine published a widely read article on the use of Laser Beam Powder Bed Fusion (PBF-LB) technology for precious metal jewellery production. Today, the continuing rise of sinter-based AM technologies promises to open up the jewellery sector yet further, with new opportunities for both mass-market production as well as bespoke pieces. Chiara Armbruster, Sonja Kappler, Carlo Burkhardt, Gerald Mitteramskogler and Apollinaria Frydmann offer an overview of this new generation of solutions and the state of the technology. A number of application examples are also presented. ... 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:

  • Back to the future: A decade of Additive Manufacturing innovation and growth at Materials Solutions
  • Win or lose: A CEO’s reflections on Artificial Intelligence and Additive Manufacturing
  • AMS 2025 New York: A reality check for the Additive Manufacturing industry
  • Optimising powder removal in PBF-LB Additive Manufacturing: A Digital Twin approach
  • ValCUN’s MMD: A robust, wire-based aluminium AM technology for defence and industrial applications
  • Enhancing quality and reliability in metal Additive Manufacturing: The role of laser calibration

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About Metal Additive Manufacturing magazine

Metal AM magazine, published quarterly in digital and print formats, is read by a rapidly expanding international audience.

Our audience includes component manufacturers, end-users, materials and equipment suppliers, analysts, researchers and more.

In addition to providing extensive industry news coverage, Metal AM magazine is known for exclusive, in-depth articles and technical reports.

Our focus is the entire metal AM process from design to application.

Each issue is available as an easy-to-navigate digital edition and a high-quality print publication.

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.

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