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September 26, 2020Ways to design a more efficient heat exchanger with Metal AM

Thermal management of complex systems is one of the most common engineering challenges. From small electronic devices to large industrial installations, transferring, storing and dissipating excessive heat are common problems that can find widely diverse solutions.               While bigger industrial heat exchangers still resort to conventional manufacturing techniques, Metal […]

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July 24, 2020What you can and cannot do with additive manufacturing in Formula 1 – Author: Davide Sher, Founder & CEO at 3dpbm

Motorsports, and Formula 1 in particular, is considered one of the driving segments for AM adoption. But one thing is the ability to rapidly produce lighter AM car parts and an entirely different thing, especially in F1, is the ability to actually use them. That’s because the regulations for additive manufacturing in Formula 1 are […]

July 21, 2020Optimising a Formula 1 aerodynamic wing by simulation

Metal additive manufacturing (AM) is widely used in Formula One, motorsport and racing to manufacturing complex parts in a short time. Powder Bed Fusion – PBF technologies, such as selective laser melting – SLM (also known as direct metal laser sintering – DMLS), are currently used to manufacture parts (e.g. exhaust systems, aerodynamic inserts and […]

May 26, 2020How Formula 1 teams benefit from metal additive manufacturing: the example of Alfa Romeo

The key success factor in Formula One is the efficient development of new components and their immediate production. The development departments of Formula One teams were among the first to experiment with additive manufacturing and to explore the dimensions of the technology. Metal AM is the first choice when lightweight components with complex structures and […]

May 5, 2020Improving Fatigue Life of Metal AM parts

High-Cycle Fatigue (HCF) is one of the most critical issues in mechanical engineering: from the first studies on railway axles to the infamous De Havilland Comet, this phenomenon led to some of the most tragic failures in the history of mechanics. Centuries of science and investigation led to a much better understanding of fatigue life […]

November 12, 2019Lattices – Why they enhance internal geometries

3D metal printing allows users to create very intricate forms easily. By tinkering with the internal geometries of printed parts they can achieve impressive mechanical properties. One of the best ways to achieve good strength-to-weight ratios, desirable shock and sound absorption and larger surface areas is to print objects with lattice structures. Why Lattices? What […]

November 12, 20192D vs 3D x-ray digital scanning: a complex choice between two complementary techniques

The continuous increase in complexity and size of 3D printed parts requires a careful analysis of the methodologies used to verify their integrity. Among these, special importance is covered by X-ray inspections. Traditionally, without destructive testing, full metrology has only been performed on the exterior dimensions of components, such as with a coordinate-measuring machine (CMM) […]

November 12, 2019We have successfully implemented Scalmalloy, ductile as titanium, light as aluminium

Materials engineers perfectly know the potential of scandium as an alloying ingredient in aluminium alloys. At the end of the 50s, Soviet scientists developed the first scandium-containing alloys, aeronautic engineers learned what scandium could do to aluminium and implemented it on MiG-21 jet fighters, the most-produced supersonic jet aircraft in aviation history, and subsequently on […]

August 12, 2019ADDITIVA wins at Silverstone with UNIMORE

Formula Student, which is run by the Institution of Mechanical Engineers, challenges students to use their creativity and technical skills to design, build and race small-scale formula-style racing cars and to compete in static and dynamic events that test their preparation and hard work. This year Formula Student returned to Silverstone UK on the 17-21 July, […]

July 22, 2019Redesigned for Additive Manufacturing: serial production of a new fuel swirler for Siemens gas turbine

Whilst the principles of Design for Additive Manufacturing (DfAM) may suggest ‘clean-sheet’ components are the best way to reap the benefits of AM technology, many examples of redesigns have brought significant performance and economic benefits. In this article, Ray Huff and Terry Wohlers report on further success at Siemens in the use of AM for […]

June 16, 2019Scalmalloy is too expensive and design optimisation only makes sense in aerospace. True or false?

Additive Manufacturing is not a cheap production process. The software, machine time, materials and expertise required to make the most of the technology all come at a significant cost. The resulting financial pressures may give rise to the temptation to select a material on its price and view advanced topology optimisation as a luxury. As […]

May 20, 2019BMW Individual employs metal AM brake callipers

BMW Individual Manufaktur has presented a new one-off vehicle which incorporates metal additively manufactured brake callipers. The BMW Individual M850i Night Sky was designed to mark the Quadrantids meteor shower which took place in January 2019, with the inclusion of illuminated constellations on the centre console and the use of meteoric material, deposited on earth […]

May 10, 2019Bugatti reveals range of metal AM components developed for its high-performance sports cars

The high-performance sports car manufacturer, Bugatti Automobiles S.A.S, headquartered in Molsheim, France, is reported to be using Additive Manufacturing to develop and build a number of functional compo­nents for its iconic range. In addition to a previously announced brake caliper, which entered vehicle trials in the first half of 2018, the company has used AM […]

February 2, 2019Binder Jet metal Additive Manufacturing: process chain considerations when moving towards series production

With the launch of a number of new systems targeting the series production of components, Binder Jetting is generating a high level of interest in the world of metal Additive Manufacturing and beyond. In the following report, Sebastian Boris Hein, Claus Aumund-Kopp and Bastian Barthel of Fraunhofer IFAM review the main process considerations and production […]

December 10, 2018Binder Jetting and FDM: a comparison with Laser Powder Bed Fusion and Metal Injection Moulding

In recent years there has been a surge in interest in the use of Binder Jetting and Fused Deposition Modelling for the production of low to medium volumes of metal additively manufactured parts. In the following report, Maximilian Munsch, Matthias Schmidt-Lehr and Eric Wycisk of Ampower GmbH & Co. KG, Hamburg, Germany, review how the […]

November 25, 2018Siemens metal AM gas turbine burner completes successful first year of operation

The first gas turbine burner to be produced by Siemens using Laser Powder Bed Fusion (LPBF) metal Additive Manufacturing has now been in operation for over 8,000 hours, having completed its first full year of active service in an SGT-700 gas turbine at E.ON’s combined cycle power plant in Philippsthal, Germany. To-date, Siemens stated that […]

November 10, 2018Airbus Helicopters begins series production of A350 passenger aircraft components

Airbus Helicopters, Donauwörth, Germany, which manufactures the doors for all Airbus aircraft programmes, has begun production of latch shafts for the doors of the Airbus A350 passenger aircraft using metal Additive Manufacturing. The latch shafts are made in titanium on an EOS M 400-4 system in batches of twenty-eight per build. The resulting parts are […]

September 29, 2018How process parameters drive successful metal AM part production

A number of factors drive the selection of process parameters in Laser Powder Bed Fusion (LPBF). In this invaluable resource Marc Saunders, Renishaw plc’s Director of Global Solutions Centres, details how these parameters define the ‘operating window’ in which AM users must work, and offers advice on identifying the ideal process parameters for metal AM […]

September 2, 2018An introduction to metal powders for AM Manufacturing processes and properties

As the AM industry grows, so does the number of metal powder suppliers and the range of different powder types that are available. In the following article Toby Tingskog presents a beginners’ guide to understanding metal powders for AM. Topics include powder manufacturing processes, sphericity, chemistry and measurement technologies, as well as considerations in relation […]

August 20, 2018Medtronic launches platform for Additive Manufacturing of complex titanium spinal implants

Medtronic plc, Dublin, Ireland, has launched a titanium Additive Manufacturing platform which it states enables more complex designs and integrated surface technologies for spinal surgical implants. The announcement was made during the American Association of Neurological Surgeons (AANS) annual meeting in New Orleans, Louisiana, USA. The new platform, titled TiONICTM Technology, is an Additive Manufacturing […]

July 12, 2018Volkswagen identifies key automotive applications

Volkswagen Group, headquartered in Wolfsburg, Germany, recently reported on the present and future applications it has identified for metal Additive Manufacturing in automotive production. In the report, Volkswagen stated that, like many companies, the primary benefit of AM has so far been in the rapid production of prototypes and one-off parts in very small lot […]

May 22, 2018Sauber Motorsport AG and Additive Industries: Formula 1 engineering meets metal AM

As the new Formula 1 season gets underway, Additive Manufacturing will have played a vital role in the development and manufacture of the cars on track. Metal AM magazine’s Nick Williams recently visited Sauber Motorsport AG at its headquarters near Zürich, Switzerland, and discovered how a partnership with Dutch AM technology supplier Additive Industries has […]

May 4, 2018NASA completes hot-fire testing of RS-25 rocket engine with metal AM component

NASA and Aerojet Rocketdyne have completed hot-fire testing of an RS-25 rocket engine containing its largest metal additively manufactured component to date. During a 400-second test at Stennis Space Center, Mississippi, USA, Aerojet Rocketdyne was able to evaluate the performance of its metal additively manufactured vibration damping device, known as a ‘pogo accumulator assembly’. It […]

May 4, 2018Porsche Classic supplies replacement parts using metal AM

Porsche Classic, based in Stuttgart, Germany, a division of Porsche AG dedicated to classic vehicles, has begun producing rare, replacement parts by metal and plastic Additive Manufacturing. Traditionally, where a spare part is no longer available, it would be reproduced using the original tools or, if the original tools are not available, replacements would be […]

February 12, 2018Beyond particle size: Exploring the influence of particle shape on metal powder performance

In recent years much effort has been put into developing powders that are optimised for AM processes. As a result, a far greater understanding of the complex requirements for powders now exists. Particle size is widely recognised as a key property, but there is also an appreciation that particle shape has an important role to […]

December 18, 2017Combining Metal AM and Hot Isostatic Pressing (HIP): application and process innovations

A technical session at the Euro PM2017 conference, held in Milan, Italy, October 1-5, 2017, investigated three different concepts in processes that combine metal Additive Manufacturing with Hot Isostatic Pressing (HIP). In the following report, Dr David Whittaker reviews three papers that consider the use of SLM for the manufacture of HIP capsules, HIP as […]

November 11, 2017Metal AM parts in series production for BMW’s new i8 Roadster

  BMW Group’s newly launched i8 Roadster features a lightweight metal additively manufactured cover carrier. The part is used to carry a cover which unfolds when opening the roof of BMW’s advanced open-top hybrid sports car. Manufactured from AlSi10Mg0.5 in a Powder Bed AM process, the part offers increased stiffness and reduced weight. Each i8 […]

April 28, 2017Built for speed

In a sport where fractions of a second count, motor racing teams are turning to additive manufacturing to make their cars faster. Beth Harlen investigates

March 13, 2017TransFIORmers Moto2™ team benefits from metal 3D printing technology

In the world of MotoGP™ motorcycle racing, technical enhancements can have a big impact.   Moto2 team TransFIORmers is using cutting edge metal additive manufacturing (3D printing) technology in an unconventional front suspension system to gain a significant competitive advantage.

March 8, 2017AUDI: Lunar Rover gets the green light for launch next year

Because terrestrial roads apparently aren't challenging enough, Audi has partnered with a group called Part-Time Scientists to launch a lunar rover. The partners previously discussed a 2017 launch, and now it looks like that might actually happen.

March 8, 2017Additive Manufacturing – Concept to Production by SIMULIA

Changing the Design Process Additive manufacturing has not only changed the way things are being built, but how they are designed. SIMULIA CTO Bruce Engelmann believes that additive techniques have the potential to revolutionize the manufacturing industry, such as Henry Ford did with the automotive industry back in the early 1900s. “Before Henry Ford the […]

March 3, 2017Airbus partition built in pieces for weight savings

The large component was successfully produced within a limited build envelope thanks to connection features designed into the pieces. Advances in powder-bed build size will permit greater efficiency in producing parts such as these. Though consolidating assemblies into one piece is one of the potential benefits of AM, this success with additive went in the […]

March 3, 2017Laser Sintering vs Laser Melting

As I introduce people to metal additive manufacturing, I have to disabuse them of the idea of laser sintering. The metal additive process that most people are thinking of is melting, not sintering.   Sintering is the process of compacting and forming a solid mass of material by heat and/or pressure without melting it to […]

February 12, 2017Terry Wohlers talks about the evolution of the 3D printing industry

Industry stalwart, Terry Wohlers, Founder and President at Wohlers Associates, talks to TCT Group Editor, Daniel O'Connor following his Formnext powered by TCT conference keynote, about how the additive manufacturing industry has evolved, particularly over the last few years, from a tool for prototyping to a production technology. Terry talks about how GE's recent investment in two major AM companies has played a significant role in validating the technology and how the next frontier for the industry is about taking these [...]

February 8, 2017Metal AM for lighter and more compact engines

A team of Renault Trucks engineers and designers is working on an additive manufacturing process - metal 3D printing - that is set to boost the performance of engines. Technology of the future is fast becoming a reality, as can be seen from the complex parts that have already been successfully tested inside a Euro 6 engine.

November 8, 2016DXV luxury bathroom faucets

The first commercially-available residential faucets created with additive manufacturing, better known as 3D printing. Masterful designs offer an exclusive, luxury faucet experience and collection with industry-leading and innovative approach to manufacturing. Pushing the boundaries of what's possible. Elevating the experience of everyday living.

November 3, 2016Testing the reusability of titanium powder

Researchers ran the same batch of powder through build after build, evaluating it each time. The results support the viability of AM for ongoing production.

September 20, 2016Metal AM for conformal cooling

In injection moulding, the cooling time of a finished product can constitute up to 70%  of the cycle time in series production. Metal AM gives mould tool designers the freedom to design complex cooling channels that closely follow the component surface, while maximising laminar flow and eliminating dead-spots that might otherwise clog up over time. Using  Metal AM technologies it's possible to integrate optimised conformal cooling channels into the mould during the production process. This ensures faster and more even [...]

September 3, 2016SLM achieves weight reduction for robot actuator

Selective Laser Melting (SLM) allowed the part to be grown in titanium TI6Al4V as one piece, reducing manufacturing operations and improving performance through design features such as curved flow tubes that eliminate right-angle drilling, all while realizing the weight reduction.

July 7, 2016Knee surgery’s next step

“Only additive manufacturing can produce this part at an affordable price, and also offer the freedom to make design changes on the fly,” says Jim Duncan, Dr. Piasecki's business partner and CEO of DanaMed Inc., the medical device company founded to develop and produce the Pathfnder System...

June 8, 2016Concept Laser on automating the Factory of Tomorrow at RAPID 2016

Concept Laser showcased its vision for the Factory of Tomorrow and M2 additive manufacturing platform at RAPID 2016 in Orlando.

March 20, 2016Concept Laser M2 cusing Multilaser

The M2 cusing Multilaser is designed in line with ATEX guidelines and thus make it possible to reactive materials safely. Like all machine solutions from Concept Laser, the M2 cusing Multilaser also boasts physical separation of the process chamber and handling area to make them user-friendly and safe to operate. The machine is robust and […]

March 8, 2016AIRBUS: innovation revolution using 3D printing technology

Airbus is at the start of an innovation revolution using 3D printing technology. 3D plastic parts are already flying on a commercial A310 and an A350 XWB test aircraft. Metal parts for wing slats, a section of the tail wing and door hinges have also been made with 3D printing. In the coming years the technology will allow manufacturing costs to fall while lighter parts will mean less fuel burn for airlines.

February 17, 2016Disruptive solution in 3D printing metal powder production technique

3D Metal printing powders need to have different properties for different applications such as particle shape & size, good flow, low oxygen content, and high oxidation resistance. Some of these problems are easy to solve while some are a tough nut to crack for the industry. Below we have discussed the top three challenges and […]