QuesTek Innovations LLC, Evanston, Illinois, USA, the primary operating arm of QuesTek International LLC, Cambridge, Massachusetts, has been awarded first place in the AM Bench 2025 modelling ... Read more »
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. ... Read more »
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. ... Read more »
At the 21st Plansee Seminar, it became clear that Additive Manufacturing has firmly established itself within the refractory metals and hard materials community. Presentations covered the full process spectrum – from powder handling and melt pool modelling to in-situ control and post-processing – with results directly relevant to industrial adoption. As Bernard North reports, work on molybdenum, tungsten, rhenium and niobium highlighted practical paths toward dense, reliable components for energy, aerospace and nuclear fusion technologies, marking a decisive step from laboratory feasibility to engineered applications. ... Read more »
While AI is accelerating innovation across industries, engineering design remains slow, manual and opaque, constrained by tools such as CAD that capture geometry but not intent. In this article, LEAP 71 co-founder Lin Kayser argues that to realise the full potential of Additive Manufacturing, and enable meaningful AI in hardware development, we have to rethink how machines are designed. His solution is Computational Engineering, a system that encodes physics, constraints, and logic directly into code, transforming engineering into a scalable, intelligent process. ... Read more »
Artificial Intelligence is reshaping industries, and Additive Manufacturing is no exception. For CEOs, the challenge isn’t just understanding AI’s potential but strategically integrating it to drive efficiency, innovation, and competitive advantage. In this article, Henning Fehrmann, chairman and CEO of FEHRMANN Tech Group, considers AI’s real-world impact on AM. Drawing from personal experience, he offers insights on how AM industry leaders can leverage AI to strengthen their businesses, adapt to market shifts, and stay competitive ... Read more »
As Additive Manufacturing pushes the boundaries of design, post-processing remains a major challenge – in particular powder removal in Laser Beam Powder Bed Fusion (PBF-LB). But what if the digital twin of a part could not only optimise its design, but also predict and streamline powder removal? Here, Joseph Kowen explores how Solukon’s SPR-Pathfinder software achieves this, using advanced simulation to map powder flow and automate depowdering, ensuring that even the most intricate designs remain manufacturable. ... Read more »
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 »
In the race to improve the productivity of PBF-LB Additive Manufacturing, machine OEMs have generally taken the path of adding more lasers. nLIGHT takes the view that it’s not necessarily just more lasers that are needed, but beam-shaping lasers. By using dynamic beam shaping technology, significant increases in the productivity, stability and metallurgical capabilities of PBF-LB have been demonstrated. Given the technology’s recent commercial success, with adoption by Aconity3D, AMCM, EOS and DMG Mori, we asked the nLIGHT team to review beam shaping technology and its potential impact on the AM industry. ... Read more »
In this joint study by Carl Zeiss AG, AMiquam SA, and EOS GmbH, the performance of eddy currents as a tool for the in-situ detection of defects in Laser Beam Powder Bed Fusion (PBF-LB) has been assessed. Process variations, including lack of fusion and keyhole formation could be detected in-situ, as well as individual defects as small as 0.3 mm post-build and post-polishing. Here, Jonatan Wicht, Harald Krauss, Frank Widulle, Julian Schulz, and Edson Costa Santos, Alain Berthoud, and Bernard Revaz present their latest findings. ... Read more »
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 »
China’s Additive Manufacturing industry is growing at extraordinary speed, driven forward by intense domestic competition and AM technology’s role in the country’s national manufacturing strategy. Based on a recent visit to the TCT Asia 2024 exhibition, Joseph Kowen shares an outsider’s perspective on what is happening in the Chinese metal AM industry. Are Chinese AM machines now rivalling those from the West in terms of capability, and how is an increasingly complex geopolitical situation impacting the dynamics of the AM industry? ... Read more »
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