IHI Europe, part of the global engineering company IHI Corporation, has expanded its additive manufacturing (AM) capabilities with Freemelt E-PBF technology, accelerating the development of next-generation high-performance materials for aerospace and energy applications.
IHI was one of Freemelt’s earliest adopters, acquiring its second-ever machine in 2019 and adding a second system in 2023. According to Dr. Rachel Jennings, Head of Advanced Technology Development at IHI Europe Ltd., the decision was driven by Freemelt’s unique open-architecture design, which allows researchers full control over process parameters and rapid experimentation with both commercial and proprietary alloys.
“Freemelt’s open platform enables us to push the boundaries of what is possible in high-temperature materials. It gives us the flexibility to experiment with small batches of novel alloys cost-effectively and at speed—something rarely achievable with conventional additive systems.”
— Dr. Rachel Jennings, Head of Advanced Technology Development, IHI Europe Ltd.
Advancing High-Temperature Alloy Development
IHI is focusing on nickel-based superalloys and advanced gamma titanium aluminides, materials crucial for components such as turbine blades operating under extreme conditions. The ability to work in a clean, high-vacuum environment makes Freemelt’s E-PBF technology particularly suited for these reactive alloys, ensuring superior performance and durability.
One of the lab’s flagship projects involves IHI TiAl 823, a proprietary gamma titanium aluminide alloy designed for low-pressure turbine blades. By shifting development from traditional powder metallurgy and forging to additive processes, IHI aims to reduce machining costs and enhance competitiveness with established nickel-based alternatives.
Despite challenges such as powder charging phenomena in reactive alloys, IHI has achieved significant breakthroughs in collaboration with other academic and industrial partners, including the Tohoku University and CEIT in San Sebastián Spain. Their work on powder modification and atomization techniques has shown promising results in improving conductivity and process stability, paving the way for broader applications across multiple AM processes.
Beyond technical progress, Jennings emphasized the importance of Freemelt’s collaborative approach: “Freemelt’s philosophy has always been to co-develop with their customers. Their openness and responsiveness have allowed us to adapt the technology to our needs while benefiting from a strong user community.”
Enabling Sustainable Manufacturing Innovation
Looking ahead, IHI sees additive manufacturing as a key enabler of sustainable, high-performance solutions across aerospace, energy, and industrial machinery sectors. With Freemelt E-PBF technology enabling faster R&D turnaround times and reduced material waste, AM is becoming increasingly integral to IHI’s innovation strategy.
“E-PBF enables the fabrication of novel high-temperature, high-performance materials that allow us to push the boundaries of applications,” Jennings concluded.
Freemelt acts as a reliable partner for companies and research institutions, supporting them from the very first decision, whether an open EBM system and the material of interest are the right fit. To help evaluate technical feasibility early, the company currently offers free sample parts for initial testing.
About IHI Europe Ltd.: IHI Europe Ltd (IEL) is the European regional office of IHI Corporation, a global engineering conglomerate founded in Japan in 1853. The office oversees sales, procurement, business development, and R&D activities across Europe, leveraging local networks to drive innovation.
About Freemelt: Freemelt is a Swedish deep-tech company specialising in open-source electron beam additive manufacturing solutions. The company develops modular, research-friendly systems used by universities, research institutes, and industry leaders for advanced materials development and sustainable production.
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