Dyndrite, a leading developer of next-generation additive manufacturing software, and Elementum3D, manufacturer of advanced 3D printing materials, have collaborated to introduce a revolutionary method for porous metal 3D printing of components with controlled permeability. The new approach enables manufacturers to create parts with both porous and solid sections in a single build, allowing for precise coolant flow while maintaining structural integrity.
This breakthrough in additive manufacturing comes as Elementum3D chooses Dyndrite LPBF Pro end-user software to integrate its patent-pending PermiAM process. The technology empowers Laser Powder Bed Fusion engineers to print different parameter strategies within various volumes of the same part, eliminating the need for assembly and reducing potential failure points.
PermiAM Tech in Porous Metal 3D Printing
PermiAM technology, developed collaboratively by Astrobotic (formerly Masten Space Systems) and Elementum3D, creates metal components that seamlessly integrate regions of controlled permeability with fully dense structures within a single part. This capability offers significant advantages for applications in hypersonics and rocket engine injectors.
By controlling part porosity during production, engineers can construct customised fluid control systems with optimised performance for extreme applications. This simplifies design steps and reduces costs compared to traditional manufacturing methods. The technology has already demonstrated success through hot fire testing of a PermiAM-based 3D-printed fuel injector, marking a substantial advancement in additive manufacturing for aerospace applications.
The technology will be integrated within Dyndrite LPBF Pro software as a plug-in, allowing engineers to apply PermiAM to parts in complex ways, including curved 3D paths, amorphous geometries, and functionally graded transitions between porous and solid materials. Both companies will partner in testing and validating physical printed demonstrators.
Applications Beyond Aerospace
While developed with aerospace in mind, PermiAM holds potential for numerous industries requiring intricate fluid control components. Commercial jet engines, automotive fuel injection systems, and data centre cooling applications stand to benefit from this technology.
The dual-use capability increases performance for systems where thermal protection is critical. By enabling the fabrication of parts with tailored permeability, PermiAM offers new possibilities for optimising performance and efficiency across various engineering applications.
“Integrating PermiAM into Dyndrite LPBF Pro is a significant step forward in making advanced permeability-controlled metal AM at scale a reality. Dyndrite’s computational approach to additive manufacturing enables the precise control needed to fully leverage PermiAM’s capabilities, unlocking new possibilities for industries ranging from aerospace and defence to energy and beyond.”
– Dr. Jacob Nuechterlein, President & Founder of Elementum3D
Harshil Goel, Founder and CEO of Dyndrite, described the collaboration as “what the future of digital manufacturing looks like—software defined materials working to push the boundaries of what’s possible.” He added: “By enabling and scaling Elementum3D’s PermiAM technology into Dyndrite LPBF Pro, we’re giving engineers and manufacturers unprecedented control over material properties, enabling production of concepts once thought impossible.”
Next Steps for the Technology
The PermiAM plug-in for Dyndrite LPBF Pro will be made available through Elementum3D. The company has received an AFWERX contract to commercialise the PermiAM solution for defence applications.
Both companies are currently seeking candidates from the space and defence sectors for the next phase of development, which involves working on real-world applications. The process has been tested in various materials, including aluminium, nickel, and copper alloys.
Elementum3D specialises in materials and process development, creating advanced metal alloys and metal ceramic composites through its patented reactive additive manufacturing technology. Dyndrite provides the GPU-accelerated computation engine used to create next-generation digital manufacturing hardware and software.
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