Large-format metal additive manufacturing is moving deeper into aerospace and defense as 3D Systems receives an additional $9 million to continue development of its GEN-II DMP-1000 metal 3D-printing platform.
The program is being developed in connection with the U.S. Air Force Research Laboratory (AFRL) and is focused on pushing metal powder-bed fusion far beyond the build sizes normally associated with the technology.
The additional funding extends development of the system for another two years, supporting work toward completing and demonstrating the massive platform.
A Much Bigger Metal 3D Printer
The GEN-II DMP-1000 is not a typical industrial metal printer.
The project is targeting an enormous 1-meter × 1-meter × 1-meter build volume, opening the possibility of producing much larger metal components in a single build.
Traditionally, large aerospace structures may require multiple separately manufactured components that are later joined together.
A machine of this scale could potentially allow engineers to consolidate some of those assemblies into fewer printed parts.
Scaling Laser Powder Bed Fusion
Producing a larger machine isn’t simply a matter of increasing the dimensions of an existing printer.
Large-scale metal powder-bed fusion requires precise control across a dramatically larger working area.
Engineers must address challenges involving:
• Powder distribution
• Laser positioning and consistency
• Thermal management
• Process monitoring
• Repeatability
• Material properties
• Build quality across very large components
The GEN-II DMP-1000 program is therefore as much about scaling the manufacturing process as it is about building a larger machine.
Why the Air Force Is Interested
Aerospace systems contain many complex metal components that can be expensive and time-consuming to manufacture using traditional methods.
Large-format additive manufacturing could potentially help engineers produce components with complex internal geometry, reduce part counts and shorten certain manufacturing workflows.
It could also become useful for producing replacement components when traditional tooling or supply chains make conventional manufacturing difficult.
From Prototype to Production Capability
The additional $9 million in funding is intended to continue development and demonstration of the GEN-II platform.
If the technology proves capable of delivering the required consistency and material performance at this scale, it could help move laser powder-bed fusion into a new category of manufacturing.
Instead of asking:
“Can we 3D print this small aerospace component?”
Engineers could increasingly ask:
“Can we print a significant portion of the structure itself?”
Metal Additive Manufacturing Keeps Getting Bigger
Industrial 3D printing has been steadily moving toward larger build volumes.
But scaling metal powder-bed fusion while maintaining precision presents a particularly difficult engineering challenge.
The GEN-II DMP-1000 represents an effort to combine two characteristics that historically have been difficult to achieve simultaneously:
BIG BUILD VOLUME + HIGH-PRECISION METAL PRINTING
If successful, the technology could expand the range of aerospace structures suitable for additive manufacturing.
From small metal components to meter-scale structures, the boundaries of metal 3D printing continue to move.
3DnMe — PRINT THE FUTURE
