Sauer is a member of German company DMG MORI, a worldwide leading manufacturer of metal-cutting machine tools. The companies announced a signed memorandum of understanding on July 6 in Moscow, and briefly described the innovations that the RUSAL-Sauer partnership is expected to achieve in bringing 3D technology advances to its global markets. RUSAL currently has diversified production facilities and operations on five continents, including three aluminium powder facilities, and expects to apply its 3D printing capabilities in industries that include automotive, aerospace and machine-producing sectors.

Alexey Arnautov, RUSAL's Director for New Projects, oversees the division responsible for research and testing of the new 3D printing venture. The rapidly-expanding 3D printing industry is one for which RUSAL is uniquely well positioned, given the global aluminium leader's dominance in R&D and its unwavering commitment to sustainability objectives. The advent of 3D printing technology has opened up and era of new horizons in aluminium production, with upcoming discoveries and opportunities promising to keep RUSAL and Sauer ahead of the competition.

"The key benefit of 3D printing technology is its ability to make industrial parts of any shape and complexity that cannot be produced using conventional means," according to Arnautov. What that means for manufacturers, particularly in key transportation sectors with an ever-evolving reliance on aluminium to achieve their carbon emissions reduction goals, is that 3D process advantages will help them meet their goals while boosting profitability as well. The current printing technologies rely on laser heating of the powders to build components that are difficult to die cast using other techniques. That is often the case with unusually small pieces, complicated parts, or in situations when mass production isn't yet the goal.

"With this technology, we can produce unique prototypes over a very short period of time. Also, the technology is practically waste-free," Arnautov added, stressing yet another environmental advantage to RUSAL's 3D commitment with Sauer. "By combining our efforts with DGM MORI, the largest manufacturer of hybrid 3D additive manufacturing machines in the world, to expand industrial use of the 3D technology, we hope to become a leading global player in this sector."

As part of the arrangement, RUSAL will develop aluminium alloys for their conversion into powders, which will then be tested and qualified by Sauer equipment. The parties will also perform joint assessments of the quality of aluminium, aluminium alloys and powders produced for 3D printing.

For its part, Sauer will provide the necessary equipment as well as supporting the setup of new production. The company will also handle the promotion of products made using the new technology among its own customer base.