Processing

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 »

Additive Manufacturing of hardmetals: An evaluation of potential processes for tool production

Hardmetals, also known as cemented carbides, have played a huge and often overlooked role in modern industrial development. From the first application in wire drawing dies in the 1920s, hardmetals are today universal and their application areas range from metal cutting and the machining of wood, plastics and composites to the production of glass bottles, aluminium cans and the ubiquitous ball-point pen tip. Can Additive Manufacturing make inroads into a market worth tens of billions of Euros in annual sales? Dr.-Ing. Johannes Pötschke reviews the fundamentals of hardmetal production and considers the most viable AM processes for this complex family of materials. [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 »

Freemelt AB: Open source technology to explore the potential of Electron Beam Powder Bed Fusion

A new wave of AM machine manufacturers focused on Electron Beam Powder Bed Fusion (PBF-EB) is looking to capitalise on what is perceived as a process with significant untapped market potential. One of the most prominent of these newcomers is Freemelt AB, a developer of open source machines designed to help broaden the PBF-EB material portfolio and application areas. As Metal AM magazine’s Emily-Jo Hopson-VandenBos reports, co-founders Ulric Ljungblad and Ulf Ackelid have no doubt as to the opportunities ahead. [First published in Metal AM Vol. 6 No. 2, Summer 2020] ... Read more »

Unrealised potential: The story and status of Electron Beam Powder Bed Fusion

In January, Boeing’s new 777X aircraft made its maiden flight, powered by two GE9X engines from GE Aviation. Whilst this was a major moment for both companies, it was also a huge milestone for Electron Beam Powder Bed Fusion (PBF-EB), and the culmination of decades of process and material development work at the driving force behind the technology, Arcam AB. Whilst the many turbine blades used in the GE9X engine are the highlight of the first chapter in the story of PBF-EB, there is also a lingering sense of unrealised potential. Here, Joseph Kowen considers the story to date and highlights a new generation of firms working to increase the technology’s adoption. [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 »

Binder Jetting and beyond: Optimising the use of metal powders for Additive Manufacturing

The high cost of metal powders for Additive Manufacturing makes them a primary focus for cost management. Learning how to treat and store such powders in order to maintain and optimise their performance and value is one way to improve production economics. Here, Dr Rajeev Dattani, from Freeman Technology, UK, and Dr Animesh Bose, Desktop Metal, USA, review how to test powders in order to develop this knowledge, and examine treatment and storage regimes that can be beneficial. [First published in Metal AM Vol. 6 No. 1, Spring 2020] ... Read more »

Alloys by Design: The future of materials for Additive Manufacturing

There is no shortage of Additive Manufacturing machines humming away in research laboratories, producing test pieces and exhibits for trade shows, but the hard truth is that relatively few are making components for serial production. In part, this is because the world is still waiting for materials which enable the technology to fulfil its true potential. In this article, Rebecca Gingell and colleagues from OxMet Technologies, Oxford, UK, explain how the company is approaching the design of novel alloys for AM, and reflect on its progress so far. [First published in Metal AM Vol. 5 No. 4, Winter 2019] ... Read more »

From silicone and rubber to steel and ceramic: the weird and wonderful world of wipers

In powder bed Additive Manufacturing processes, the recoater system is responsible for spreading a fine and even layer of powder for each layer of a build. This system typically uses wipers to create the necessary surface, with the variants of wipers used being almost as diverse as the number of AM machines on the market. Olaf Diegel and Terry Wohlers explain why it is not only machine operators, but also designers and engineers, who need to be aware of the weird and wonderful world of wipers. [First published in Metal AM Vol. 5 No. 4, Winter 2019] ... 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:

  • Mauro Antolotti and BEAMIT: The story of Italy’s leading AM parts producer and its founder’s view on the industry
  • Why do we need Women in 3D Printing? The what, the who, and the why of the blog that became a movement
  • The need for speed, and how the right powder can reduce AM part production costs by 50%
  • Metal Additive Manufacturing:
    Why standards lay the foundation for continued industry growth
  • The advantages of Additive Manufacturing for the processing of platinum group metals
  • Obstacles to the adoption of metal AM by small- and medium-sized enterprises
  • Additive Manufacturing of aluminium parts by Directed Energy Deposition: Possibilities and challenges
  • Euro PM2020 technical review: Advances in process control for metal Binder Jetting (BJT)
  • > More information

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