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Additive Manufacturing Media

We are the media brand devoted to industrial applications of 3D printing technology. Instead, we speak to a manufacturing audience.

Additive Manufacturing is devoted to industrial applications of 3D printing and digital layering technology to make functional parts. We don’t cover 3D printing as it relates to making design models, movie props, sculpture or swimwear (sorry). We are exploring the use of additive manufacturing to make tooling, molds and functional prototypes, along with the ultimate aim of manufacturers: end-use p

roduction parts. We report on the promise of additive manufacturing in these applications. We also report on the pitfalls. Staff members write about successes with additive manufacturing and the hard roads that led to those successes.

07/03/2024

FreeForm Technologies runs 22 binder jetting machines. Peter Zelinski shares more on the company's downstream workflow.

06/27/2024

🎧 Full episode: https://www.additivemanufacturing.media/articles/additive-manufacturing-at-nasa-(part-1)-am-radio-51?utm_source=facebook

In this first episode of a two-part AM Radio special on additive manufacturing at NASA - National Aeronautics and Space Administration, we discuss three specific 3D printed parts for upcoming missions and share observations about the organization’s approach to AM.

06/24/2024

Metal bellows are flexible metal junctures for connecting machine components that might need to expand or move. They are typically manufactured by forming tubes of sheet metal (image one), but this process relies on tooling that limits design possibilities and can make the bellows costly.

Mechanical engineer Dr. Günter Kappler has developed metal bellows that can instead be manufactured via laser powder bed fusion (image two).

Learn more about the 3D printed version here: https://www.additivemanufacturing.media/articles/flexible-bellows-made-through-metal-3d-printing-the-cool-parts-show-64?utm_source=facebook

06/24/2024

In laser powder bed fusion, applying multiple materials separately within the same build seems as though it should be impossible.

After all, the “bed” of the powder bed machine is an undifferentiated mass of powder, offering no capacity to segregate separate materials.

But, Schaeffler Aerosint offers a system that brings this segregation to LPBF machines — and Penn State University’s CIMP-3D is exploring applications of the system for multimaterial 3D printing.

More here in a short article and video by Peter Zelinski:

Penn State University’s CIMP-3D is exploring applications of the Aerosint system for multimaterial 3D printing. I got an introduction to this system.

06/18/2024

The part you see in the image is a drawbar.

It's a component in the milling spindle of a CNC machine tool and is often plated for wear resistance. But, the drawbar seen here was made by DMG MORI and is covered by a hard layer of high-speed steel applied via directed energy deposition (DED).

The company says eliminating chrome plating by an external supplier, and consolidating all the drawbar’s steps into one machine tool, cuts the drawbar’s production cost by 80%, cuts lead time by over 90%, and cuts carbon dioxide emissions associated with making this part by two-thirds.

New process for multimetal drawbar replaces plating with directed energy deposition, performed with roughing, finishing and grinding on a hybrid machine.

06/10/2024

NASA’s RAMFIRE (Reactive Additive Manufacturing for the Fourth Industrial Revolution) project commissioned Elementum 3D to work closely with NASA engineers and scientists and RPM Innovations, Inc. to develop and print a 36-inch diameter aluminum aerospike rocket nozzle out of A6061-RAM2 material.

NASA - National Aeronautics and Space Administration
Elementum 3D

NASA's RAMFIRE project has additively manufactured a 36-inch diameter aerospike nozzle with complex integral coolant channels, which NASA engineers will use as a proof of concept to inform future component designs.

06/05/2024

Quadrus Corporation, an expert in additive manufacturing of high-value parts for the United States Department of Defense, often must change from one exotic material to another in its powder bed machines. Cleaning is a core competency.

More lessons from this company’s system for working with an ever-changing mix of 3D printed alloys are at: https://www.additivemanufacturing.media/articles/quadrus-powder-management-tactics-for-tungsten-rhenium-and-other-am-alloys

05/29/2024

Events are about audience!

Formnext Chicago offers unmatched access to both existing additive manufacturing adopters AND industrial manufacturers that represent future AM growth.

⚡ See the 5 Formnext Steps to Building the Additive Manufacturing Event for Your Business here https://www.formnextchicago.com/5-steps

⚡ Then check out the Formnext Founders already committed to Formnext Chicago 2025 here: https://www.formnextchicago.com/founders-club

_______

is organized by Additive Manufacturing Media, Gardner Business Media, Inc. and AMT - The Association For Manufacturing Technology, and is licensed by Mesago Messe Frankfurt GmbH, which brings you Formnext each fall.

05/28/2024

Skuld LLC brings a new, 3D printing-enabled version of lost foam casting to market via its turnkey package for metal manufacturers.

Skuld LLC applies 3D printing to its Additive Manufacturing Evaporative Casting (AMEC) process; a new approach to lost foam casting that provides metal manufacturers with cost-effective, sustainable and time-efficient metal parts.

05/25/2024

Indy 500 🤝 3D printing
The 108th running of the Indianapolis 500 takes place on May 26. This year, the cars on the track feature a new 3D printed component: the next generation of the titanium top frame that holds the aeroscreen and protects the driver in the event of a rollover.

We tell its manufacturing story on The Cool Parts Show!

🏁 See the full episode at TheCoolPartsShow.com 🏁

____
The Cool Parts Show is sponsored by Carpenter Additive

05/23/2024

This custom 3D printed furniture startup founded in 2018 has matured in its product offerings as well as its manufacturing equipment, moving from homegrown 3D printers to industrial large-format machines.

The startup founded in 2018 has matured in its product offerings as well as its manufacturing equipment, moving from homegrown printers to industrial Titan machines.

05/20/2024

🏁 The 108th running of the Indianapolis 500 takes place on May 26. This year, the cars on the track feature a new 3D printed component: the next generation of the titanium top frame that holds the aeroscreen and protects the driver in the event of a rollover.

The top frame is a newer addition to Indycar vehicles, but has improved the safety of the sport. Its next gen maintains performance at 7 lbs lighter.

05/16/2024

Wind power shafts that might once have been scrapped are now returned to service thanks to the robotic directed energy deposition (DED) and shaft preheating system developed by Ikergune, IZADI and Talens Systems.

Wind power shafts are now fixed and returned to service. See the robotic directed energy deposition (DED) system developed by Ikergune, Izadi and Talens.

05/13/2024

Exhibitors and presenters at the plastics show emphasized 3D printing as a complement and aid to more traditional production processes.

Here are four observations on 3D printing at NPE by AM executive editor Stephanie Hendrixson.

Exhibitors and presenters at the plastics show emphasized 3D printing as a complement and aid to more traditional production processes.

05/09/2024

LPBF 🤝 DED

went to NASA's Marshall Space Flight Center to learn about the 3D printed thrust chamber assembly 🚀

📺 Full episode at www.TheCoolPartsShow.com

__

05/09/2024

Laser powder bed fusion and directed energy deposition combine for an integrated multi-metal rocket propulsion system that will save cost and time for NASA. The Cool Parts Show visits NASA's Marshall Space Flight Center.

is sponsored by Carpenter Additive.

Laser powder bed fusion and directed energy deposition combine for an integrated multi-metal rocket propulsion system that will save cost and time for NASA.

05/07/2024

3D Printing vs. Cavitation
(Cavitation never stood a chance.)

05/04/2024

🐎 The greatest 2 minutes in sports! Today is the Kentucky Derby and whether you plan to watch or not, we suggest betting on...3D printed horse trailers.

https://bit.ly/3JG3lRf

This 3D printed prototype horse trailer will be made with robot-enabed large-format additive manufacturing. See the trailer and the print setup.

05/03/2024

Additive Manufacturing Media will be covering all things at NPE. Stay tuned for coverage and follow along at .

05/03/2024

Ergonomics and Economics of Really Big Laser Powder Bed Fusion

As laser powder bed fusion (LPBF) machines get larger, they introduce new challenges when it comes to the ergonomics and economics of 3D printing metal parts from powder. This video filmed at CIMP-3D, the Center for Innovative Materials Processing through Direct Digital Deposition located at Penn State, looks at a large-format “factory” built around a 3D Systems DMP500 3D printer with a build area measuring 500 x 500 mm.

To deal with the heavy build plates, large amounts of powder and big parts produced, this machine is surrounded by a collection of peripherals. This equipment includes a Build Breakout Station, Powder Recycling Module, specialized wire EDM, and a transportation module to move material and builds ergonomically. While this machine can be applied to make very large parts, its more economical application might be to produce multiple smaller parts at once.

05/02/2024

Rather than adapting production methodologies to additive manufacturing, this Pennsylvania contract manufacturer adapts AM to production methodologies. In general, this starts with conversation.

Rather than adapting production methodologies to additive manufacturing, this Pennsylvania contract manufacturer adapts AM to production methodologies.

05/01/2024

A lot can happen in six years. A lot HAS happened in the six years since the last NPE — and we've invested in covering the ways industrial 3D printing has progressed in that time, including the developments that have advanced the plastics industry.

Additive Manufacturing Media will be on-site at covering the new ways plastics manufacturers are finding success with 3D printing.

Follow along with our coverage at .

04/30/2024

It's called Hìtëkw — the Lenape term for “tree” — and it's the tennis racket with a branchlike 3D printed frame.

Protolabs

A collaborative project between All Design Lab and Protolabs conceptualized the the design for an aesthetic, yet functional 3D printed tennis racket to push the mold for design capabilities within additive manufacturing.

04/23/2024

With the launch of the Factor 4 this week at HANNOVER MESSE, the new UltiMaker is expanding its ecosystem further into industrial manufacturing territory.

Current and expected uses for this platform include durable automation tooling, CNC machining fixtures, replacement parts and small runs of end-use items.

AM executive editor Stephanie Hendrixson visited UltiMaker to see the Factor 4 and noted several key features.

The company’s Factor 4 3D printer introduced this week is designed to complement conventional manufacturing equipment including CNC machining and automation.

04/13/2024

Are you a molder, toolmaker or OEM looking to adopt 3D printing? Here are 7 lessons about this technology that will be explored during our AM Workshop at NPE.

Are you a molder, toolmaker or OEM looking to adopt 3D printing? 7 lessons about the tech to be explored during a workshop at NPE2024: The Plastics Show.

04/12/2024

Perhaps the ultimate surface-area challenge is in bioengineering. The Southwest Research Institute develops bioreactor scaffolds that could only be made using .

See them on !

The Cool Parts Show is sponsored by Carpenter Additive.

The ultimate surface-area challenge is in bioengineering: growing a enough cells in a compact volume to be effective for leading-edge medical treatments.

04/04/2024

Retrieving a part from the Digital Inventory Service by Würth Additive Group is more than accessing a build file — the system creates a complete "recipe" for each part.

This recipe documentation is customizable to the user’s requirements and can include:
🔹 a list of required equipment, including PPE, printer, material and any postprocessing implements.
🔹 guided steps for postprocessing and quality control, prompting the operator to confirm compliance at every step.

Würth Industry North America

The DIS enables distributed, on-demand manufacturing for OEMs and companies of all sizes through secure data transfer and detailed production processes.

04/02/2024

How has a family-owned manufacturer of fiberglass composite bathtubs and showers integrated additive manufacturing into the workflow?

Lyons Industries, Inc, Massivit 3D

Aiming to increase automation, Lyons Industries acquired a Massivit 10000 to quickly produce high-performance molds and support fixtures.

03/20/2024

Baker Hughes is realizing shorter lead times and simplified manufacturing through powder bed fusion. The energy technology supplier is using to produce valve trims previously assembled from many machined metal parts. See them on The Cool Parts Show!

is sponsored by Carpenter Additive.

Baker Hughes is realizing shorter lead times and simplified manufacturing through powder bed fusion to produce valve trims previously assembled from many machined metal parts.

03/07/2024

One of the challenges with generative design is the computational power required. But, what if there was an expert system that already “knows” the right or nearly right geometry for a given problem, so that no generative design and therefore significantly less computation is needed?

New Ohio facility is where geometric cells are tested to inform the machine learning that will “know” what 3D printed form satisfies a given set of needs.

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Videos

FreeForm Technologies runs 22 binder jetting machines. Peter Zelinski shares more on the company's downstream workflow. #additivemanufacturing #3Dprinting #metal #metal3Dprinting #manufacturing

🎧 Full episode: https://www.additivemanufacturing.media/articles/additive-manufacturing-at-nasa-(part-1)-am-radio-51?utm_source=facebook In this first episode of a two-part AM Radio special on additive manufacturing at NASA - National Aeronautics and Space Administration, we discuss three specific 3D printed parts for upcoming missions and share observations about the organization’s approach to AM.

Quadrus Corporation, an expert in additive manufacturing of high-value parts for the United States Department of Defense, often must change from one exotic material to another in its powder bed machines. Cleaning is a core competency. More lessons from this company’s system for working with an ever-changing mix of 3D printed alloys are at: https://www.additivemanufacturing.media/articles/quadrus-powder-management-tactics-for-tungsten-rhenium-and-other-am-alloys

Indy 500 🤝 3D printing The 108th running of the Indianapolis 500 takes place on May 26. This year, the cars on the track feature a new 3D printed component: the next generation of the titanium top frame that holds the aeroscreen and protects the driver in the event of a rollover. We tell its manufacturing story on The Cool Parts Show! 🏁 See the full episode at TheCoolPartsShow.com 🏁 ____ The Cool Parts Show is sponsored by Carpenter Additive #thecoolpartsshow #coolparts #additivemanufacturing #3Dprinting #indy500 #indianapolis500 #vroomvroom #3Dprintedtitanium

LPBF 🤝 DED #TheCoolPartsShow went to NASA's Marshall Space Flight Center to learn about the 3D printed thrust chamber assembly 🚀 📺 Full episode at www.TheCoolPartsShow.com __ #coolparts #additivemanufacturing #3Dprinting #NASA #rockets #propulsion #LPBF #DED #metal3Dprinting #spacecraft #combustionchamber #RAMPT #NASARAMPT

3D Printing vs. Cavitation (Cavitation never stood a chance.)

Ergonomics and Economics of Really Big Laser Powder Bed Fusion As laser powder bed fusion (LPBF) machines get larger, they introduce new challenges when it comes to the ergonomics and economics of 3D printing metal parts from powder. This video filmed at CIMP-3D, the Center for Innovative Materials Processing through Direct Digital Deposition located at Penn State, looks at a large-format “factory” built around a 3D Systems DMP500 3D printer with a build area measuring 500 x 500 mm. To deal with the heavy build plates, large amounts of powder and big parts produced, this machine is surrounded by a collection of peripherals. This equipment includes a Build Breakout Station, Powder Recycling Module, specialized wire EDM, and a transportation module to move material and builds ergonomically. While this machine can be applied to make very large parts, its more economical application might be to produce multiple smaller parts at once. #additivemanufacturing #3Dprinting #LPBF

A lot can happen in six years. A lot HAS happened in the six years since the last NPE — and we've invested in covering the ways industrial 3D printing has progressed in that time, including the developments that have advanced the plastics industry. Additive Manufacturing Media will be on-site at #NPE2024 covering the new ways plastics manufacturers are finding success with 3D printing. Follow along with our coverage at #COVEREDinPT.

Get all of the access to The Cool Parts Show. The Cool Parts Show All Access is our free email for fans of the show who want to dig deeper. Each issue comes with exclusive perks, including early notice every time we drop a new episode ✨ links to exclusive extra videos related to the newest episode ✨ commentary from one of your friendly co-hosts ✨ behind-the-scenes trivia, contests and giveaways ✨ the chance to submit your questions to our experts for upcoming episodes. Want all of the Cool Parts access? Sign up for All Access here https://www.additivemanufacturing.media/kc/cool-parts/allaccess?utm_source=facebook #thecoolpartsshow #coolparts #3Dprinting #additivemanufacturing The Cool Parts Show is sponsored by Carpenter Additive.

Feat of strength? Electroplating 3D printed polymer parts can improve their strength and impart desired properties such as electrical conductivity, EMI shielding and abrasion resistance. AM Executive Editor Stephanie Hendrixson explains from her visit at RePliForm. More about it here: https://www.additivemanufacturing.media/articles/possibilities-from-electroplating-3d-printed-plastic-parts?utm_source=facebook&utm_medium=Social&utm_campaign=social23&utm_content=Featofstre #3Dprinting #additivemanufacturing #electroplating

Additive manufactured metal parts often face greater scrutiny than conventional castings or forgings. Formalloy believes these parts should be more readily accepted, however, because a DED printer equipped with sufficient monitoring capability allows for gathering data about every step along the way. More here: https://www.additivemanufacturing.media/articles/making-sense-of-data-from-directed-energy-deposition-(ded)?utm_source=facebook&utm_medium=Social&utm_campaign=social23&utm_content=formalloy #additivemanufacturing #3Dprinting #DED #metalAM #metal3Dprinting #castings #forging

3D printing elastomers onto textiles is not only possible, it's practical, too, as we saw at Formnext. Application: 3D printing onto textiles Designed and manufactured by: Chromatic 3D Materials Anouk Wipprecht Material: Chromaflow 70 #additivemanufacturing #3Dprinting #textiles #3Dprintedfashion #elastomer

Mobile cobots as the solution for loading and unloading 3D printers in print farms? Peter Zelinski visited the Print&Go and Branch Robotics booth at Formnext to see cobots in action. #Formnext #Formnext2023 #3Dprinting #cobots

STEP 3D Printing at Fathom Manufacturing's facility in Fremont, California. More at: https://www.additivemanufacturing.media/articles/video-step-3d-printing-at-fathom-manufacturing

Powder particles of different sizes can be used in metal 3D printing. Most powders for metal 3D printing are made up of particles of similar size. This ensures repeatable density and performance. But, Additive Manufacturing Media executive editor Stephanie Hendrixson visited a company (Uniformity Labs) that offers materials that are made up of particles in different sizes. These multimodal powders can pack more densely in the bed of a laser powder bed fusion or binder jetting 3D printing. Uniformity Labs says this leads to reduced porosity, more efficient use of lasers and binder, and even improved material properties. Want to know more about multimodal powders and Uniformity Labs' approach? See it here: https://www.additivemanufacturing.media/articles/multimodal-powders-bring-uniform-layers-downstream-benefits-for-metal-additive-manufacturing-

We are one week away from announcing the WINNERS of The Cool Parts Showcase 🏆 Watch Stephanie and Pete's recap of the finalists and then VOTE if you haven't already. thecoolpartsshow.com/showcase 🗳️ Don't forget — you can see the finalist parts in person at Formnext Forum Austin next week! ✨ Thank you to The Cool Parts Showcase sponsor, Carpenter Additive ✨ #coolparts #thecoolpartsshow #thecoolpartsshowcase #formnextforum #formnextforumaustin

We can't talk about additive manufacturing without talking about materials. Materials offer maybe the greatest area of design freedom in additive. At Formnext Forum Austin, Jacob Nuechterlein of Elementum 3D will talk about new possibilities for metals in additive manufacturing, new metal alloys, metal ceramic composites and the way forward into production with these materials. Come join us. Hear him speak. Meet Jacob. #FormnextForum is our conference and networking event in Austin, Texas, August 28 through 30. It is for manufacturing leaders. It is all about additive manufacturing for production. Sign up at www.formnextforum.com #ffa23 #ffa2023 #3Dprinting #additivemanufacturing

Is a 3D printed part strong and durable enough to do the job? If you've ever asked yourself or your team that question, you might be interested in one of the speakers coming to Formnext Forum Austin. Matt Sanders is going to be speaking in the main track about qualification testing and what it can teach us about the strength and performance of additive parts. Matt is a qualification engineer at Stress Engineering Services, a company who — as the name might suggest — specializes in figuring out when, where, how and why parts will fail. #FormnextForum is an event for manufacturing leaders. It is for companies that are already using additive, as well as those looking to adopt. Typically, qualification is a big part of that decision. So come learn from Matt and our other great speakers. You can find all the information at www.formnextforum.com #ffa23 #ffa2023

Eaton stood up an aircraft part production facility using additive manufacturing. They did this because of the advantages additive brings in speed, cost, supply chain resiliency, design freedom. It wasn't easy. At Formnext Forum Austin, director of additive manufacturing Michael York is going to talk about Eaton's journey with additive — the struggles, the challenges, the successes. Hear him speak and meet him. #FormnextForum is our event all about #additivemanufacturing for production. It's for manufacturing leaders. Join us August 28 through 30 in Austin, Texas. Details at formnextforum.com

Carolyn Seepersad, professor of mechanical engineering at The University of Texas at Austin, is going to be talking about design, specifically in terms of process awareness, iterations and computational design in additive manufacturing at Formnext Forum Austin. A conference and networking event for manufacturing leaders, Formnext Forum will be held in Austin, Texas, August 28 through the 30, offering a diverse platform of speakers with expertise from various tracks in the additive space. AM editor Fiona Lawler recently had the pleasure of speaking with Carolyn, who explained a project she's currently working on, namely the discovery of innovative 3D printing techniques to reimagine the design of complex medical devices, such as pediatric breathing masks. Learn more about Carolyn's presentation and #formnextforum at https://www.formnextforum.com/ We hope to see you there. #FFA2023 #formnextforum #ffa23 #additivemanufacturing #3dprinting

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About us

Additive Manufacturing is the media brand devoted to industrial applications of 3D printing and digital layering technology to make functional parts. We don’t cover 3D printing as it relates to making design models, movie props, sculpture or swimwear (sorry). Instead, we speak to a manufacturing audience. We are exploring the use of additive manufacturing to make tooling, molds and functional prototypes, along with the ultimate aim of manufacturers: end-use production parts. We report on the promise of additive manufacturing in these applications. We also report on the pitfalls. Staff members write about successes with additive manufacturing and the hard roads that led to those successes.