Aluminum and aluminum alloys are considered to be one of the most promising materials for the next phase of the development of additive manufacturing into high-volume production applications. This is mainly due to aluminum’s excellent mechanical properties and low price compared to lightweight metals such as titanium alloys. However, the industrial application of additively manufactured aluminum-based parts is still a long way off because several inherent challenges faced by aluminum 3D printing have not yet been effectively addressed.
Aluminum alloy powder magnified to 100 microns
Meanwhile, wild swings in aluminum prices, production and supply have plagued supply chains in recent months, especially as global tensions rise amid the Russia-Ukraine conflict. The first is that Russia is a major supplier of aluminum to the global market, with Russia’s largest manufacturer RUSAL supplying 40% of the EU’s aluminum needs. Second, aluminum smelting is a power-intensive process and has therefore been affected by the recent energy crunch. In some cases, additive manufacturing can provide solutions for supply chain resiliency by reducing the amount of material required to produce certain additively manufactured parts.
Aluminum 3D printing materials and technologies
An early challenge with aluminum 3D printing is that almost all aluminum alloys used for additive manufacturing were originally developed for casting applications. In fact, the most commonly used aluminum alloy in additive manufacturing to date is AlSi10Mg, an age-strengthened aluminum alloy with good hardness, strength and dynamic toughness that has been traditionally used as a casting alloy. Powders made from AlSi10Mg are commonly used in additive manufacturing and the final components have high corrosion resistance, low density and high mechanical strength.
Common commercial aluminum alloy materials for additive manufacturing and related technologies, source: 3dpbm Research
Aluminum materials for laser powder bed fusion (L-PBF)
For common aluminum alloy materials, most hardware companies and service providers use L-PBF technology for processing. For example, American company VELO3D has developed a process for 357D printing parts made of aluminum F3 using its Sapphire system. This creates new opportunities for cast-grade aluminum alloys, particularly for thin-wall heat transfer applications in the aerospace and defense industries. Aluminum F357 was considered an ideal material because of its ability to be anodized and its similar properties to the popular casting alloy A357. Around the same time, as part of a collaboration between Honeywell and SLM Solutions, a newly developed aluminum alloy F357 parameter package AlSi7Mg0,6 (a new beryllium-free version of the A357) showed significant improvements in material properties compared to parts produced by die casting. To improve. Honeywell and SLM Solutions announced a collaboration in 2019 to develop 3D printing based on metal powder bed fusion with high-layer thickness, aiming to reduce manufacturing time and cost of producing 3D printed aircraft parts to meet the requirements of the aerospace industry.
△A20X was developed specifically for additive manufacturing. ECKART, part of ALTANA Group, now commercializes globally after acquiring raw materials developer AMT
Only recently have aluminum alloys specialized for additive manufacturing started to gain market adoption. The first and most popular is Scalmalloy, which was developed and marketed by aerospace specialists APWORKS (now part of Premium AEROTEC). Globally, service providers with Scalmalloy manufacturing capabilities are mostly metal additive manufacturing giants, such as 3T and Zare (acquired by BEAMIT), SauberEngineering, Metron, https://www.3dprintingbusiness.directory/company/toolcraft/ , PolyShape (now part of AddUp), Pankl, and Quadrus Corporation.
Another popular aluminum alloy material for additive manufacturing is A20X, which was developed specifically for additive manufacturing and can provide tensile strength up to 511 MPa, yield strength up to 440 MPa and elongation at break up to 13% . A20X is commercialized globally by ECKART, a subsidiary of Altana Group, following the acquisition of raw materials developer AMT.
Electric motorcycle frame, also printed by APWORKS using its scalmalloy alloy
Ahead of the Russia-Ukraine conflict, RUSAL, one of the world’s largest aluminum manufacturers, has launched the ALLOW range of aluminum products for additive manufacturing, which includes casting alloys and several alloys developed specifically for additive manufacturing processes, and is targeted at sustainable Optimized for performance and low energy consumption needs. These include RS-230 AlCu, a 2xxx series alloy that is resistant to hot cracking, and RS-390 AlSiNi alloy, suitable for applications up to 250°C; and RS 507 AlMg and RS-553AlMgSc alloys, which are corrosion-resistant, high-strength Materials, price is significantly lower than Scalmalloy. While the threat of a total ban on Russian aluminum has not yet taken effect, it is unclear what the commercial prospects are for RUSAL aluminum powder, which produces 6% of the world’s aluminum.
In 2020, French company Constellium launched Aheadd, a new generation of optimized high-performance aluminum powder for L-PBF. Among them, Aheadd CP1 (Al-Zr-Fe) is the preferred solution when high conductivity and increased productivity are required. Advanced HT1 (aluminium-manganese-nickel-copper-zirconium) is the solution for high temperature and strength requirements.
In addition to A20X, ALLOW and Aheadd, Equispheres, a power manufacturer from Canada, has also simultaneously launched high-performance, high-fine aluminum powder products for additive manufacturing (this is the brand name of each product and its intended use). The company developed a completely uniform, perfectly spherical powder that improves process reliability, production speed and part performance in additive manufacturing, targeting the opportunity of high-volume, lightweight additively manufactured parts. Equispheres has also partnered with TRUMPF, LockheedMartin, Aconity3D and Morf3D to accelerate development.
Binder injection of aluminum materials
Equisphere’s aluminum powders require no modifications or additives to be sintered. This provides performance advantages on the binder jet printer platform. The binder jet process has been hailed as a breakthrough technology that will take additive manufacturing to the next level, and these inherently sintered aluminum powders will open the door to mass production of lightweight parts.
This brings up the new topic of aluminum binder jetting. As metal PBF processes become increasingly efficient through larger, faster and more automated systems, the adoption and demand for aluminum alloys is expected to grow significantly. However, a major challenge to widespread adoption of aluminum in additive manufacturing is that high-throughput binder jetting is a manufacturing process that enables high-volume production, an advantage amplified by aluminum’s low cost. In terms of material development, most of the materials used in high-throughput binder jetting were initially adapted from metal materials used in the injection molding (MIM) process. However, binder jetting technology for aluminum and its alloys has not yet been developed. develop.
△Aluminum engine block model with high resolution and geometry 3D printed in 6061 material through a new binder jet 3D printing and sintering process jointly developed by Ford and ExOne (now part of Desktop Metal) (in progress) Apply for patent) Manufacturing
As with traditional MIM, in binder jetting, metal powder is first mixed with a binder to make it moldable or additively manufactured parts. The green parts are then sintered in a furnace. The adhesive is removed and the oxide layer is heated and reduced. Metal powders join to form a solid object. Sintering of aluminum is challenging because the oxide layer around the particles can only be removed at extremely high temperatures, and aluminum has a relatively low melting point, which limits the maximum sintering temperature. Therefore, it is very challenging to remove the oxide layer on the aluminum powder before the entire metal piece is melted.
Solutions to this problem have been explored for several years, but full commercialization of aluminum as an adhesive sprayable material remains elusive. Today, however, that may be changing. In early 2021, two binder jetting companies, Desktop Metal and ExOne (now merged), each made major breakthroughs in aluminum 6061 sintering, and used binder jetting technology to produce parts of related materials.
The new aluminum 6061 powder developed by Desktop Metal is capable of complete sintering and is a significant improvement over previous techniques for aluminum sintering, which required coating powder particles, mixing sintering aids into the powder, and using binders containing expensive nanoparticles. Or add metals like lead, tin and magnesium. Crucially, Desktop Metal’s powder is also compatible with water-based binders and has a higher minimum ignition energy (MIE) than other commercially available 6061 aluminum powders, resulting in improved safety. Desktop Metal and Uniformity Labs are working to validate the commercial viability of powder and scale production. Once fully qualified, Uniformity6061 aluminum will be available for desktop metal production system platforms.
The potential of aluminum as a binder jetting material is huge, and Ricoh has so far focused its entire metal additive manufacturing strategy on this specific area. While its technology is not yet commercially available, it has demonstrated the ability to produce complex and sizable parts.
Aluminum materials that can be used for dynamic consolidation
Another Australian company, SPEE3D, supports high-speed, large-format 3D printing of (non-spherical) aluminum powders (including 6061, 5056 and 7075) through its supersonic 3D deposition technology, a type of kinetic consolidation (aka cold spray) powder). This is the name of a patented process in which a turbine nozzle accelerates air to three times the speed of sound, injecting metal powder into it and then depositing it onto a substrate manipulated by a six-axis robotic arm. During this process, the sheer kinetic energy of particles striking each other causes the powder to bond together, forming high-density parts with metallurgical properties superior to those of casting.
3D printing aluminum using wire as raw material
Aluminum alloys can also prove to be valuable and cost-effective materials in high-throughput WAAM (Wire Arc Additive Manufacturing) processes. The use of various aluminum alloys in various types of WAAM technologies is currently an active area of research. Recent research shows that the most promising alloys are AlLi, AlCu, Al-Mg, AlZnMgCu, AlCuMg, AlSiMg, AlMgSi and AlMgMn/AlMg5Mn (these alloys are of particular interest due to their high strength and corrosion resistance). Several wire-based metal DED companies around the world also list aluminum as a key material.
AML3D is an Australian company that sells WAM (Wire Additive Manufacturing) technology through the Arcemy system, which supports the use of aluminum alloys in multiple wire forms, specifically 2319, 4043, 5183, 5183 (0.2% Sc), 5356 and 5087. The WAM process is characterized as the standard for direct energy deposition in 3D printing. Compared to other wire-fed metal printing technologies such as electron beam, wire-fed laser and laser sintering processes, WAM can be used in open free-form manufacturing environments using localized inert gases. Print metal parts, thereby reducing manufacturing costs while improving material properties.
△AML3D’s large-format Arcemy system
MX3D, the Dutch leader in WAAM technology known for a variety of high-profile applications, has certified a wide range of aluminum materials for which its WAAM technology is compatible (available through Production Services and M1 Hardware Systems). These include AlSi10Mg (4046) and AlSi7Mg (4018) as well as 5356 and 5087 in wire form. WAAM3D is a British company that has recently entered the market with its advanced and highly automated roboWAAM system, also offering aluminum wire (2024 and 5087).
These alloys are listed as “Level 3” materials for WAAM1D’s CMT-WAAM (Cold Metal Spray) process, which means the company has set key process parameters specific to the material to ensure the correct geometry is printed without defects. They are also available as “Level 3” materials for WAAM0D’s PTA-WAAM (Plasma Transfer Arc) process, which means users must choose the process parameters for their own R&D.
Meltio is a fast-growing company selling high-speed, low-cost wire-based additive manufacturing systems that currently does not offer aluminum among its supported materials. It’s also worth noting that Xerox recently abandoned its ElemX project, which was based on a liquid metal printing method, and focused on aluminum as the primary material for the technology’s applications and growth strategy.
In the US, MELD, a growing startup focused on defense applications, has developed a solid-state process (meaning the material does not reach melting temperatures during the process) to produce high-quality materials with low residual stress and full density materials and parts, and have lower energy requirements than traditional fusion-based processes. The MELD process is capable of printing large metal parts at a scale not yet seen in the metal additive manufacturing market, and deposits material at least 10 times faster than fusion-based metal additive processes. MELD’s first commercial machine, the B8, uses solid metal rods but can also combine different powders to create metal matrix composites (MMC), such as Al-SiC, Al-Fe, Al-W, Al-Mo.
△New roboWAAM system from British WAAM3D
Among materials suppliers, voestalpine Böhler’s additive manufacturing materials portfolio includes non-specified aluminum wire for WAAM. However, the production of aluminum materials in WAAM technology is still often limited by defects such as porosity and solidification cracks, which can severely limit the mechanical properties of the component, such as component strength or ductility. Recently, a startup called Fortium Metals entered the market building on Elementum 3D’s experience and focusing on metal wire for additive manufacturing. The company specializes in providing “ideal metallurgy for weldable non-weldables” by solving the problems of hot tearing and hot cracking, including 1xxx, 2xxx, 6xxx and 7xxx series aluminum.
Applications of 3D printed aluminum parts
The metal 3D printing industry will continue to experience growth as metal developers and manufacturers introduce more aluminum and aluminum alloy materials specifically designed for additive manufacturing. Today, although the application potential of aluminum additive manufacturing remains largely unexplored, it is making progress in some areas.
Scalmalloy was developed specifically for aerospace applications and has the characteristics to meet the harsh application environment. Aluminum-magnesium-scandium powder alloy has a high strength-to-weight ratio, good ductility and corrosion resistance. Used in conjunction with topology optimization, the material can provide lightweight, high-performance aircraft components. It’s also worth mentioning that back in 2016, APWORKS used this aluminum alloy to create a 3D printed motorcycle, the Light Rider.
△3D printed aluminum spare parts used in Mercedes-Benz trucks
In the automotive and motorsports fields, aluminum alloy 3D printing technology is being applied. One notable example is the window rails on the BMW i8 Roadster. The metal parts are made from an aluminum alloy, which is lighter than the injection-molded plastic parts typically used, but is still much stiffer. Its importance has been recognized by the ALTAIR Enlighten Award. Another key application is that Mercedes-Benz 3D printed one of the first spare parts for its truck division in 2017. Another key initiative also dates back to 2017, with the participation of Daimler, EOS and Premium Aerotec partners in the NextGen AM project, whose main goal is to advance the automation of industrial 3D printing processes, with a particular focus on the qualification of aluminum for industrial 3D printing identified. The project ended in 2019 as the companies said they had gained important insights.
Motorsport is another high-growth area for additive manufacturing, where aluminum components can play a role. In 2020, Formula 1 approved the use of two Elementum 3D aluminum powders (A6061-RAM1 and A2024-RAM2) for Season 1. Elementum 3D’s A6061-RAM2 alloy is also used by aerospace startup Masten Space Systems to produce 3D printed electronic pumps.
△The Czinger21 supercar was developed by Divergent in collaboration with SLM Solutions. Each car has up to 350 3D printed parts, most of which are made of aluminum alloy.
The luxury and supercar automotive sector continues to be the most accessible area for aluminum 3D printing technology, especially L-PBF technology. Most notable is the ongoing collaboration between Divergent and SLM Solutions on the Czinger21 supercar, with up to 350 3D printed parts on each car, the majority of which are made from aluminum alloys.
Also noteworthy in the automotive sector is the German EDAG Group, which in 2020 worked with eight partners to develop aluminum alloys for 3D printing of automotive parts. Metallic CustAlloy is designed to be “collision resistant” and has higher strength and elongation at break than other additively manufactured aluminum materials. With an eye on wider applications in mass-market vehicles, Ford and binder jetting specialist ExOne (now part of Desktop Metal) have developed a method to 3D print aluminum 6061 using binder jetting and sintering it. The process is capable of producing parts with a density of 99% and is patent pending.
Aluminum alloys also have countless applications in industry, including the production of heat exchangers and radiators. Australian additive manufacturing company Conflux Technology has demonstrated how additive manufacturing and aluminum alloys can be used to produce more efficient heat exchangers. Specifically, the company demonstrated a 10D printed heat exchanger manufactured using an EOS M3 290D printer and EOS’s AlSi3Mg material. The now-patented heat exchangers have a variety of applications in a range of industries, including aerospace, automotive, oil and gas, chemical processing and microprocessor cooling.
△MELDManufacturing CEO Naci Hardwick with metal 3D printed parts.
Large-format wire-based applications (mainly via WAAM technology) include the aluminum keel project, which is part of an ongoing collaboration between KM Yachtbuilders and MX3D to research and 3D print aluminum parts for the maritime industry. The aluminum 3D printed keels were produced using the company’s robotic WAAM (Wire Arc Additive Manufacturing) process. Another recent project saw MX3D launch the Arc Bike II, a 3D printed aluminum bicycle.
When it comes to large format aluminum printed parts, the largest to date are produced by MELD Manufacturing. The US company used its unique friction bond 3D printing process to demonstrate the scalability of its open-air capabilities by printing a ten-foot (3.05 meter) diameter aluminum cylinder using off-the-shelf aluminum strips.
△Aluminum 3D printed keel provided by MX3D for KM yacht manufacturer
Quantifying aluminum additive manufacturing business
By reviewing every additive manufacturing product on the market today, 3dpbm Research has created the most accurate overview of the metal additive manufacturing market based on shipment records for each major material family. This provides the basis for the 10-year forecasts for specific material families in the recently released Metal Additive Manufacturing Market Trends and Opportunities report.
The report shows that the fastest growing material families in additive manufacturing are aluminum and copper. Aluminum has been widely used in powder AM processes, but until recently, almost all aluminum AM powders on the market, including the most popular AlSi10Mg, were cast alloys suitable for AM processes. Starting from Scalmalloy launched by APWORKS in 2016 and the new generation aluminum alloy A20X specially developed for AM, it has entered the market.
The main obstacle to adopting aluminum in additive manufacturing is adapting the material to the bonded metal process. Binder jetting (BMP) processes will become the largest consumer of additively manufactured aluminum alloys as these technologies target cost-effective high-volume production. But the BMP process still requires the step of sintering the green parts in a furnace, which remains a challenge that is only now starting to be addressed.
In terms of metal additive manufacturing material demand forecasts, the most obvious change is the rapid growth of aluminum alloy applications. Today, aluminum alloys are the fourth most popular alloy after steel, titanium and nickel, with 249 tons shipped in 2021, an increase of +36% compared to 2020. They will become the third most popular alloy by 2030, when they will account for nearly 20% of total metal additive manufacturing materials shipments, at 5,354 tons. If binder jetting technology proves capable of processing aluminum proficiently for volume production, the increase in aluminum demand may be even more significant.
Aluminum alloys was the fourth largest materials segment in terms of revenue in 2020, generating just $17.9 million and growing 36.8% in 2021, allowing us to better understand the size of the additive manufacturing materials market. While growth will be significant, due to the small quantities required to produce parts via 3D printing, and the parts typically produced via additive manufacturing in small quantities, either prototypes and tooling (often one-offs) or small batches Production parts.
With this in mind, it’s clear from the variety of potential applications and uses that aluminum additive manufacturing is destined to grow dramatically this decade. Among currently mature metal additive manufacturing materials, aluminum alloys are expected to have the highest CAGR of 33.3%, followed by titanium, steel, nickel and cobalt alloys. This will make aluminum and its alloys the third most relevant revenue opportunity by the end of the forecast period, generating $321 million in annual sales by 2030 (a growth of more than 1,700%).