At the heart of Alcoa's initiative to capitalize on 3D printing is its trademark Ampliforge process, which involves combining 3D printing with more traditional manufacturing techniques (such as forging). Through Ampliforge, Alcoa 3D prints a mostly complete part and then finalizes it with the use of traditional techniques that enhance its qualities.
With this approach, 3D printed parts can be made stronger and more durable than they would be after purely additive manufacturing. At the same time, the hybrid process uses significantly less material and a simpler production process than would otherwise be needed when solely using traditional methods.
The $60 million investment being made in Alcoa's new research facility could potentially pay off with major dividends for the company. As a major player in the aluminium market, Alcoa has had to deal with prices for raw aluminium dropping, even as demand for finished parts in aerospace, automotive, and other industries has grown rapidly.
Aluminium 3D printing
INNOVATION
In September 2015, US aluminium giant Alcoa made headlines by announcing it would invest $60 million in a new, specialized manufacturing center dedicated to 3D printing techniques and materials.
18 January, 2016
Located in Pittsburgh, Pennsylvania, the new manufacturing center will join Alcoa's existing research and development facilities and will work to make 3D printing more applicable to largescale manufacturing needs.
Alcoa's chief technology officer Ray Kilmer explains that alloys currently available for use in "additive printing" (which works by depositing one layer of material on top of another) are too expensive for widespread use: "The (alloy) powders need to be improved upon, they need to be cost effective, and they need to work better in the additive printing process. What's new now is the machines are getting better, faster and cheaper. Alcoa is stepping into the process so we can get the performance and the cost to where they need to be." Alcoa's new facility will create and test new aluminium, titanium, nickel, and other alloys to find more economical metal solutions.
Photo by Alcoa
With the primary metals market struggling, Alcoa has come to see the manufacturing of highly-specialized parts as a road to diversifying its product line. The company has already been working with 3D printed materials for two decades, and recently acquired RTI International Metals in order to boost its capabilities in working with titanium and other advanced materials. The new 3D printing research facility, which is slated for completion in early 2016, will employ over a hundred people and include material, design, and technology experts within its team.
Alcoa is investing in the next generation of 3D printing for aerospace and beyond. Combining our expertise in metal alloys, manufacturing, design and product qualification, we will push beyond the limits of today's additive manufacturing. This investment strengthens our leadership position in meeting fast-growing demand for aerospace components made using additive technologies
Klaus Kleinfeld
Alcoa CEO
Alcoa is not the only company to turn to 3D printing as a means of reducing wasted materials and making its manufacturing process more cost effective. Norway's Norsk Titanium AS also plans to open an industrial-scale 3D printing plant in the US, while General Electric will begin incorporating 3D printed parts into aircraft engine platforms in 2016. Building off the efforts of both companies, Norsk Titanium and Alcoa have teamed up on a joint 3D printing Industrial Cooperation Program that will take advantage of each company's core strengths in order to increase production of parts for the aerospace, defense, energy, automotive, and maritime industries.
Photo by 3D Printing Industry.
Photo by 3D Printing Industry.