A compact metal 3D printer
ETH spin-off a-metal has developed a breakthrough system for metal 3D printers, making them more compact and affordable – tailored to the needs of SMEs.
We talked to CEO Stephan Steiner
3D printers for metal are not new, but they have been affordable only for large companies. However, there is also a demand for such printers among SMEs. This would require the printers to be smaller, cheaper and easier to use. A young ETH spin-off took on this challenge.
A new system design developed from scratch
Stephan Steiner and his team have developed a new system design to make the printers smaller. Instead of the usual three areas for the feeder, the building chamber and the overflow, the engineers developed a concept in which the feeder for the powder is eliminated. At a-metal, the powder is filled into cartridges and located directly on the recoating unit above the building area. In addition to the smaller footprint, this also has the advantage that the system is much safer and easier to operate than existing technologies. ‘Our powder cartridges, similar to a printer cartridge, offer much greater safety than loose powder because the dangerous powder particles can no longer be inhaled,’ explains Steiner. This eliminates the need for a laboratory environment to operate the device and relieves the investment budget.
“Our powder cartridges, similar to a printer cartridge, offer much greater safety than loose powder because the dangerous powder particles can no longer be inhaled.”Stephan Steiner, CEO a-metal
The recoating is applied using powder from the cartridges, with any excess directed through a small slot beside the building area into an overflow container. This container can later be mounted onto a peripheral sieving unit, allowing the powder to be sifted back into the cartridge, creating a closed, contact-free cycle with the hazardous powder.
The resulting printer is no larger than a small refrigerator and costs about 50% less than existing models. It is safe to use and requires no specialised knowledge, which is ideal for SMEs.
Many possible applications
The a-metal printer can produce components up to a maximum of 150x150x150mm. Areas of possible application include aviation, fixture construction, lightweight metal construction, injection moulding tools, and dental products. Currently, a-metal is focusing on the latter two.
Performance is crucial in injection moulding tool construction, and metal 3D printing excels by enabling complex, conformal cooling channels in the tool insert. Even a small reduction of 0.2 seconds per cycle significantly impacts the production of 100,000 parts. This can lead to a 10-20% reduction in cycle time, lowering both manufacturing costs and CO2 emissions.
Dental laboratories, however, work very customised, i.e. each part is manufactured to fit the patient perfectly. Conventional methods using milling cutters often result in bulkier, heavier components with significant material waste. Traditionally, 3D-printed parts had to be outsourced, but in-house production offers a game-changing advantage. Despite the initial investment in a printer, it reduces costs, enhances customisation, and saves valuable time.
Attractive pilot programme
For the new system concept, a-metal developed the electronics from scratch. The same applies to the mechanics, whereby they were able to draw on the results of Stephan Steiner's master's thesis. Overall, such developments are very investment-intensive, which is why a pilot programme should provide prompt and valuable feedback from the industry. a-metal has made ten pilot systems available to the SME industry at an attractive price for six months each. The first eight systems are already in operation, with the rest to follow soon. “The pilot machines provide us with feedback from a wide range of applications and industries, which is essential for the further development of our machines,” explains Steiner.
“The concept, the price and the prospect of being closely supported by a-metal in the pilot programme convinced us.”Claude Werder, President of the Board, Samuel Werder AG
Investors wanted
For a successful scale-up, a-metal is looking for industry-related investors for its seed financing round and would be pleased to hear from you.
Contact/Links:
external page a-metal
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