Thursday, April 17, 2025 Penn State Prints Two Metals in Single Complex Structure At Penn State, University Park, Pennsylvania, researchers have harnessed a groundbreaking 3D-printing technique to create complex metal structures previously achievable only through welding. This innovative method, known as multi-material laser powder bed fusion, allows the fusing of different metals into a single part.Utilizing a newly acquired system at the Center for Innovative Materials Processing Through Direct Digital Deposition (CIMP-3D), the team successfully printed a structure combining low-carbon stainless steel and bronze. The fine metal powders are applied with micron-level precision and melted using a laser. A typical one-centimeter-tall part consists of thousands of layers and requires several hours to print.Guha Manogharan, an associate professor and co-director of CIMP-3D, emphasized the importance of monitoring during the process to identify defects like porosity and cracking in real time. They analyzed the build orientation of parts, printed upright, flat or on its side, to understand how it affects quality. In printing two metals in a single powder simultaneously, researchers had to work through complex questions on processing conditions and part quality. In this paper, they focused on analyzing the build orientation of the part to understand what would change if the part was printed upright, flat or on its side.Their finished structure is a complex shape known as a gyroid, which is used in applications such as heat exchangers and biomedical implants. The researchers chose the gyroid shape to demonstrate the capabilities of the new manufacturing process. Future research will explore other metal alloys and enhance the method's robustness for production use. Previous Article 2025 WHO’s WHO in PM Membership Directory Print 257 Rate this article: No rating Please login or register to post comments.