MATERIALS TECH NEWS

3D Systems expands Metal AM Material Portfolio with Scalmalloy & M789

Metal AM Materials
Above: 3D Systems DMP Flex 350 metal 3D printer/Image Source: 3D Systems

3D Systems, one of the largest 3D printing companies in the world, announced the addition of two industry-leading metal AM materials to its portfolio; Certified Scalmalloy (A) and Certified M789 (A). These materials will facilitate demanding industrial high-strength, corrosion-resistant parts for additive applications in markets such as aerospace, motorsports & automotive, semiconductor, energy, and mould-making.

Both the new metal AM materials are optimised and compatible for metal additive manufacturing on its Direct Metal Printing (DMP) platform.

Furthermore, 3D Systems collaborated with material manufacturers APWORKS and voestalpine BHLER Edelstahl to certify these materials for use with its metal 3D printing technology. Customers can now work with the company’s Application Innovation Group (AIG) to quickly certify these materials for use with its DMP Flex 350 and DMP Factory 350 printers, giving them a competitive advantage with faster time to market.

Scalmalloy® Metal AM Material

Scalmalloy Metal AM Materials
Above: Suspension rocker produced in Certified Scalmalloy (A)/Image Source: 3D Systems

Scalmalloy is a high-strength Aluminum alloy that has a tensile strength of 520MPa and yield strength of 480MPa, significantly stronger than the reference material AlSi10Mg. The high strength of Scalmalloy makes it ideal for additively manufacturing weight-efficient, load-bearing components. Using this material, manufacturers are able to produce high-strength, corrosion-resistant Aluminum parts facilitated by fully-developed build styles available in 3DXpert® software for the company’s DMP Flex 350 and DMP Factory 350 metal 3D printers. Additionally, parts produced using Scalmalloy metal AM material can be chemically cleaned during post-processing which removes surface residue to deliver a final part with optimal surface finish. Ideal applications for this material include:

  • Aerospace: passive RF components (e.g., filters, waveguides, etc.), lightweight structural components
  • Motorsports & Automotive: metal structural components (e.g., suspension brackets, transmission casings), energy and fluid management
  • Semiconductor: fluid flow (e.g., manifolds), thermal management (e.g., cooling nozzles, wafer tables)

“Adding the capability to additively manufacture parts from Scalmalloy to our portfolio is an important step forward; especially for our aerospace customers. Scalmalloy has a very attractive strength-to-weight ratio and is more amenable to 3D printing than many conventional high-strength Aluminum alloys. These performance attributes make it ideal for aerospace applications and we are excited to see how our customers will use 3D printed Scalmalloy components to continue to push the envelope with their innovation.”

– Dr. Michael Shepard, vice president, aerospace & defense segment, 3D Systems

M789 (BÖHLER M789 AMPO)

M789 Metal AM Materials
Above: High-strength mould insert for air vents produced with metal additive manufacturing in Certified M789 (A) cobalt free tool steel/Image Source: 3D Systems

M789 metal AM material allows 3D Systems’ customers to produce high-strength moulds and tooling that can not only be hardened up to 52HRC but are also free of Cobalt. 3D Systems has attained certification of M789 for its DMP platform through collaboration with its partner, GF Machining Solutions, addressing customers’ requests for a hard, corrosion-resistant tooling steel to foster advanced applications. The resulting parts are optimal for long-term use, able to withstand both the rigours of repetitive manufacturing processes as well as use in regions with high humidity. Ideal applications for this material include:

  • Mould-making: mould inserts with conformal cooling
  • Energy: drill bits, cutting tools
  • Automotive: tire moulds, drive train parts, axle components

“Our customers in the automotive industry are increasingly relying on additive manufacturing to advance and accelerate their innovation. Having M789 as part of our metal 3D printing solution delivers greater accuracy to our automotive customers. This is enabling them to use the technology for applications that require higher fidelity and thinner walls, like die inserts with conformal cooling and tire tread moulds, and providing them a competitive advantage.”

– Kevin Baughey, segment leader, transportation & motorsports, 3D Systems

3D Systems will be attending the upcoming RAPID+TCT 2021 show to be held September 13-15 at McCormick Place in Chicago. Attendees there can visit 3D Systems in booth E7601 to further explore the advantages of these materials. Visitors will have the opportunity to not only see parts produced using these new materials but also to speak with the company’s application experts to explore how Scalmalloy and M789 can be used to meet their unique application challenges.


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