Singapore develops 3D printing alloy technology

The School of Mechanical and Aerospace Engineering at Nanyang Technological University in Singapore has made a breakthrough with the development of a new 3D printer capable of printing two different metals with varying melting points simultaneously. This innovation uses a simple material container and a specialized device, making it possible to create complex metal parts that were previously difficult or impossible to produce using traditional 3D printing methods. Earlier versions of 3D printers were limited to single-material printing, with only a few models able to handle multiple types of plastics. Printing metal alloys, especially those combining two different metals, was considered a major challenge. In this new system, each metal is stored in its own material chamber. Operators input design specifications and laser temperature settings before starting the process. The printer works by moving the material box from the inside out, spreading metal powder onto a base plate. After the laser melts the powder, another layer is added, and the process repeats until the final object is formed. When printing with two metals, a special spaced material container is used to keep the powders separate during the process. For example, when printing an alloy of steel and copper, the printer first spreads copper powder as the material box moves inward. On the return trip, steel powder is spread over the copper layer, and the laser then fuses the two layers together. The order of the powder application can be adjusted depending on the desired outcome. One of the main challenges in this method is maintaining the correct laser temperature to control how the molten metal flows. If the temperature is not properly managed, the liquid metal may not bond well, leading to voids within the printed object. These gaps can weaken the structure and reduce the adhesion between the two metal layers, resulting in a less durable final product.

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