20 May Harnessing the Power of Metal 3D Printing: Innovative Application and Future Trends
When it comes to revolutionary processes, metal 3D printing is spearheading one of the greatest manufacturing shifts in recent times. While its potential has yet to be fully realised, innovative use of the technology is bringing benefits that – even a few short years ago – were still considered the realm of science fiction.
What is Metal 3D Printing?
The process, which is also known as additive manufacturing, involves using a heat source to fuse layer upon layer of metal powder to form a shape. A laser or an electron beam provides the necessary high temperature, and the process of micro-layering makes it possible to create shapes with intricate delicacy that simply isn’t possible (or would be cost-prohibitive) by using any other method.
A wide variety of metals can be used, including:
- Aluminium
- Titanium
- Stainless steel
How Metal 3D Printing is Driving Innovation
Inventions and the creation of prototypes have always been an expensive process. The cost and fabrication of parts with intricate geometries has long been the sticking point that either prevents ideas from being explored or results in a painstakingly long process to move forward.
Until now…
Metal 3D printing removes many of the barriers that were previously insurmountable. Inventors of the past could only dream of such a process where even the most complex shape can be produced quickly, efficiently and at relatively low cost.
Examples of how the process is driving innovation include:
- One-off custom parts: Many industries require bespoke solutions to challenges. Previously, the creation of a custom part was a laborious, expensive process – one that often meant a problem went unsolved or that only companies with the deepest pockets were able to address. Custom-made parts for even a one-off use can now easily and affordably be created.
- Rapid prototyping: Designs can be quickly produced, easily altered and be available for testing within days. Such accelerated production creates an expedited marketing process, something that’s playing a huge part in the rapid expansion of technological progress. This is advantageous in both the development of and the creation of functional prototypes, allowing viable designs to be built and physically tested in real-world conditions.
- Optimised moulding and tooling: The ability to easily create intricate and complex geometries allows advanced structures, cooling channels and other improvements to be added to traditional designs. This leads to parts that perform better and last longer.
One of the greatest advantages of the process is its cost-effectiveness. This is just as relevant to the creation of prototypes and small batch production as it is to end-user parts manufacturing – especially for smaller-sized runs or individual components. Because 3D printing can use so many different mediums, it allows optimal materials that will improve aspects like weight-to-strength ratios. Such durability further lowers costs, enhances production and can play an important role in reducing asset downtime.
Other benefits include:
- Reduced wastage: Because metal 3D printing is an additive process, rather than a subtractive one, there’s far less material waste.
- Faster production times: Especially relevant for small run or bespoke part production.
- Wholly customisable: Design tweaks can easily be made without the need for drawn-out, expensive processes.
The Future Potential of Metal 3D Printing
While metal 3D printing is already fast-tracking today’s manufacturing processes, the true potential is still very much in its infancy. The possibility of what might be achievable in the future is a subject that’s undergoing extensive research.
Likely, near-future developments include:
- The development of more advanced materials: Such as composites and high-performance alloys.
- Improved printing technology: Faster processes, increased scalability and even more intricate precision.
- Sustainability: Including recyclable energy and/or using renewable energy sources, recycling metal powders and other such sustainable manufacturing processes.
- IoT integration: This is one of the most exciting areas, whereby combining the 3D printing process with AI and intelligent learning is going to lead to a cosmic jump in capabilities. Imagine, for example, an integrated digital twin—metal 3D printing process that learns and improves in the digital plane and automatically produces the optimal solution in the physical.
SixDe is at the forefront of such technology, providing innovative solutions – such as metal 3D printing – to help our customers fast-track their manufacturing efforts. Our innovative design service works with customers to determine the ultimate way forward, with an expert team that specialises in the creation of bespoke part production for even the most complex challenge.
Contact us today to discover the SixDe difference.