Metal Additive Manufacturing
We help manufacturers adopt and scale Additive Manufacturing (AM) by providing end-to-end solutions—from developing high-performance metal powders to producing precision 3D-printed components. Our global production network ensures reliable supply, industrial-grade quality, and seamless integration, making AM a practical, scalable solution for industrial production.
Overview
Metal Additive Manufacturing, often referred to as 3D printing, is a process that builds metal parts layer by layer from a digital design. Unlike traditional subtractive methods, Metal AM constructs components directly from metal powders, allowing for intricate geometries and lightweight structures that were previously difficult or impossible to manufacture.
Additive Manufacturing Process Overview
Starting with digital modeling and precise powder preparation, the process enables unparalleled design freedom and material efficiency. Components are built with precision through selective fusion or binding, followed by post-processing to enhance mechanical properties and surface finishes. AM delivers highly complex, lightweight, and customizable parts for demanding applications across industries.
The foundation of Metal Additive Manufacturing begins with precise digital modeling, material selection, and machine setup to ensure optimal part performance and process efficiency.
- Digital Modeling: Advanced CAD tools and simulation-driven design methods enable the creation of optimized parts that fully leverage AM’s potential.
- Powder Selection: High-quality, tailor-made metal powders—such as 316L, 17-4PH, and FSLA—are chosen and blended to suit specific AM processes like Binder Jetting or Laser AM.
- Machine Setup and Parameterization: Our AM systems are configured in an Industry 4.0 environment, utilizing GKN’s intelligent global print network for efficiency.
Benefit: This stage ensures that designs are optimized for additive processes and that the chosen materials and machine settings will yield high-quality, repeatable results.
Key Benefits of Additive Manufacturing Technology
- Scalability: Designed for high volumes—produce thousands of parts efficiently.
- Design Freedom & Complexity: Create intricate, lightweight structures and internal features unattainable through traditional methods.
- Speed & Flexibility: Rapid prototyping and on-demand production accelerate product development cycles.
- Material Efficiency: Near-net-shape manufacturing minimizes waste and optimizes material usage.
- Customization: Tailor each component for specific applications without costly tooling changes.
- Industry 4.0 Integration: A global print network and digital twin technology enable scalable, efficient, and high-quality production.
Additive Manufacturing vs Other Metalworking Methods
Compared to traditional manufacturing, Additive Manufacturing offers:
- Greater Complexity: Ability to produce shapes and structures that are impossible to create with subtractive or formative processes.
- Reduced Waste: Material is added only where needed, cutting down on scrap and excess waste.
- Tool-less Production: Elimination of molds, dies, and other tooling reduces lead times and upfront costs.
- Rapid Iteration: Design changes can be quickly implemented, allowing for continuous improvement and innovation.
Driving Sustainability with Advanced Powder Solutions
Powder Metallurgy (PM) delivers significant environmental benefits by reducing material waste, energy usage, and emissions through efficient, near-net-shape manufacturing processes. By recycling and reusing up to 100% of metal powders, PM conserves resources and supports sustainable production. At GKN Powder Metallurgy, sustainability is embedded in our operations, enabling manufacturers to reduce environmental impact, improve material efficiency, and achieve cost-effective solutions across diverse applications.