9JUNE 2025Current improvements and where we're headingThe adoption of metal 3D printing has naturally aligned with technology improvements and material availability. Material developmentThe current list of metals available for additive manufacturing includes tool steels, stainless steels, titanium alloys, aluminum alloys, nickel-based superalloys, cobalt-chromium alloys, and copper alloys.Material development often results from collaborations between material suppliers, AM system manufacturers, and/ or project customers. For example, Stratasys Direct Manufacturing worked with aerospace companies to characterize Copper C18150 (CuCr1Zr) on Direct Metal Laser Melting (DMLM) systems for thermal control applications in aerospace. With more collaborations on the horizon to fill in gaps for applications, it's likely that further material development will increase the niche use of AM parts in aircraft. Technology developmentDMLM system improvements have varied from technology type to technology type, but most address five key challenges the processes have faced. Compared to traditional metal manufacturing methods like machining and casting, metal additive manufacturing has struggled with dimensional accuracy, material recyclability, isotropic characteristics, stress-induced deformations, and overall build size limitations. Dimensional accuracy concerns have arrived from the inherent nature of additive manufacturing; factors related to the part geometry, material composition, machine and build chamber atmospheres, laser power, scan speeds, and build orientations all can influence a build. To combat this issue, users depend on thoroughly vetted design parameters and well-planned part orientation to achieve accuracy. Some system manufacturers such as VELO3Dhave developed their systems to address issues like to build pauses, inconsistent mechanical properties, labor-intensive quality controls, and decreased use of supports--all while avoiding deformation. Additional advancements in 3D metal manufacturing enable more design freedom, including the production of low-angle geometries and few or no support structures. The goal is to broaden the capabilities of additive metals technology as well as the economic viability of the process at higher quantities.Where we're headingWith further material and technology advancements, metal additive manufacturing will open more possibilities for advanced aerospace production and aircraft maintenance activities. Some of the biggest players in aerospace are using DMLM technology for revolutionary designs and advanced production components to help propel their industry forward. Materials development is expected to become an even bigger part of the conversation. The lack of materials diversity - and more importantly, published characterization for additive manufacturing - will inhibit widespread adoption.Regardless of the challenges, the benefits of additive metal printing far outpace the concerns, and the possibilities are wide open. The adoption of metal 3D printing has naturally aligned with technology improvements and material availabilityA 3D printed combustion liner built with a DMLM system. Courtesy of Stratasys Direct Manufacturing.A modern manufacturing floor with several DMLM systems. Courtesy of Stratasys Direct Manufacturing.
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