Metal additive manufacturing, also known as metal 3D printing, builds a three-dimensional object from a computer-aided design (CAD) model. It is built by adding metal powder material, layer by layer. This is completely different from conventional machining, casting and forging processes, where the material is removed from a stock item (subtractive manufacturing) or is poured into a mold and shaped using dies, presses and hammers.

‍Metal additive manufacturing technology can produce very complex shapes or geometries with faster product development cycles, because components, shapes or tools are printed with metal powder in one step, instead of being assembled using multiple parts.

The benefit is:

• Complex geometries can be manufactured
• On-demand replacement for components
• Increased speed and reliability of quality assurance and validation processes
• Rapid prototyping to provide a dynamic, design-driven process
• Reduced manufacturing lead times and increased productivity of critical components
• Reduced component weights through innovative geometries and new patented materials
• Stronger components with increased shear and tensile strength
• Low volume production parts
• Reduced development costs

Components can be made with highly complex shapes (such as incorporating honeycombed internal structures) to reduce weight and cost.

This means that a component can be designed with a reduced mass or improved heat exchange characteristics compared with conventional casting, forging and machining processes. Best of all, metal additive manufacturing provides design flexibility.

Yes, Amaero has a metal 3D printing manufacturing bureau service, which means we can manufacture components for you. Another option we provide is to connect you with other manufacturers who utilize our equipment, so they manufacture for you.  

Get in contact to find out more.

We use two techniques – Laser Powder Bed Fusion Selective Laser Melting (SLM) and Direct Laser Deposition (DLD) – also referred to as blown powder directed energy deposition.
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The components are produced by selectively melting fine metallic powder layer upon layer using a high-powered laser which is scanned at high speed across each layer. These methods enable components to have highly complex shapes and can incorporate internal lattice structures to reduce weight and cost.

We use a variety of post-processing applications, including:

• Heat Treatment
• Stress Relieve
• HIP (Ho- Isostatic Press)
• A variety of finishes

• ‍Abrasive Blast
• Rumbling
• Raw

We will use our expertise to apply the right post-processing application(s) for your project to ensure high quality.

Tooling refers to the fixtures, tools and accessories that are used in machine tools such as CNC machines and injection molding machines, including jigs, dies, molds and patterns.
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Agile tooling (or rapid tooling) is a growing application for metal 3D printing, where it is used to manufacture tools or tool components, or in producing molds which are then used to manufacture tools. This process significantly reduces the lead time and cost of tooling manufacture.
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Additionally, the use of metal 3D printing improves functionality by creating tool designs that were previously unobtainable or unaffordable.

Amaero has successfully printed many alloys. In fact, we have qualified more metals for the aerospace and defense industry than any other company in the world.

We print Aluminum alloys (AlSi7Mg, AlSi10Mg, Amaero HOT Al), Maraging steel (MS1), H13, 316 Stainless, 17-4 PH stainless, Hastelloy X, Hastelloy B23, Inconels (625, 718, 738) INVAR36, Cobalt Chrome alloys, Niobium alloys, Titanium alloys (Ti64, Amaero Beta Ti), Tungsten alloys and other specialized proprietary alloys on behalf of our clients.

Through our partnership with MCAM, we have patented two new superalloys for metal 3D printing (high strength titanium alloy powder and high-performance aluminum alloy powder) which offer significant benefits.
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When it comes to your requirements use a specific alloy or develop a new one, we can provide you a solution.

When it comes to your specific project, we can help select an alloy that best meets your requirements.  Get in contact to find out more.

‍Yes, metal additive manufacturing (metal 3D printing) is beneficial for many industries, including:

• Aviation
• Space
• Defense
• Tooling
• Automotive
• Transport
• Healthcare
• Dental
• Construction
• Marine
• Industrial

Get in contact to see how we can help your organization.

With the right material selection and manufacturing process, we can 3D print components that have load bearing durability requirements as well as decorative applications.
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When compared to conventional manufacturing methods (forging, casting and machining), we can achieve more complex geometries and internal features such as cooling channels, lattice structures and parts consolidation.
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The process is currently limited to a maximum build volume in a laser powder bed fusion of 800 x 400 x 500 mm, but the Direct Laser Deposition process can do larger components up to 4.5 x 1.8 x 1.5 meters.

There are software design tools that provide an indication of whether the design can be 3D printed. However, we recommend asking our team for feedback. We can confirm if there is a high or low risk of build failure and provide tips on how to avoid or mitigate these risks.

Get in contact to see how we can help your organization.

No, we do not print with polymers. However, we have worked with clients to develop composites within a metal matrix. If you need plastic 3D printing, we can refer you to another company in our network.
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Our Amaero SP series range of machines are the safest and most capital efficient. The different range of sizes enables us to provide the most cost-effective solution for specific additive manufacturing requirements.
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If you require small components, we have the SP100 with a build volume of 100 mm diameter x 80 mm Z. It is suitable for small components like dental implants or jewelry and is useful for research laboratories working on metal alloy development.
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At the large end of the scale, we will soon have the SP800, which will be able to print up to 800 mm x 600 mm x 600 mm build volume. This is will be ideal for producing components for the aerospace and biomedical industries, as well as manufacturing steel tooling.
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You may have read on our website that Amaero has purchased and optimized the parameters of their major competitors 3D printing machines.
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In fact, some of these companies asked our team to provide new operating parameters because it out-performed what they were able to create.

Our prices are competitive, depending on the size of machine you require, Amaero SP series 3D printers are generally 1.5 to 2 times more capital efficient than our competitors.
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This means on a capital cost recovery basis you can expect our machines to be half to two thirds of the price of the leading Laser Powder Bed Fusion Selective Laser Melting (SLM) 3D metal printers.

If you want pricing for a specific machine or set of equipment, complete the confidential inquiry form or contact us by email.

Yes, in addition to installing and commissioning the machine, we offer the service of optimizing the process for your product.  We can develop the process on our own machines first and then implement it in your facility.  We then train your staff to operate the equipment for your product needs.

Yes.

Yes, we can tailor a scheduled service and maintenance program to cater to your specific manufacturing needs.

We have supply arrangements with many different groups around the world. Our main suppliers of components for our 3D printers are in the EU, Japan, China and (of course) Australia.
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We also 3D print a number of specialized components for our machines. The assembly of our printers and software integration is in Notting Hill (a Melbourne suburb), in the state of Victoria, Australia.

Yes. Get in contact to see how we can help your organization.

Additive manufacturing machines require the handling of metal powders.  Many of the powders in use are hazardous to inhale or ingest and in some cases are explosive.  Amaero's systems help to separate people and powder, making them the safest available in the market.

Amaero's SP range of 3D printing machines separate people from powder, which are the first machines of its type in the world to provide this safety standard and overcome this issue.

Amaero's SP range of 3D printing machines and ancillary equipment are designed to do all metal powder handling in a controlled atmosphere. This is the first system in the world to provide this level of safety.

Our machines can manufacture the smallest of components up to the largest build volume in the world (800mm x 400mm x 500mm).

In some cases, the component may require post processing such as machining, polishing or coatings.
For other uses, the part can be used as printed or with some simple heat treatment and finishing processes.

Feel free to contact our team so they can provide suggestions on how to minimize any post- processing operations.

Whatever your additive manufacturing needs, Amaero can tailor a solution.  Whether you need powder, design services, components, tooling, machines or ancillary equipment, we have the experience and capability to provide you with the best options to meet your requirements.

We are the only fully integrated metal 3D solutions provider that is backed by the world largest R&D department.

This means we not only develop new materials, provide you with proprietary alloys and design new ways to manufacture your components, but we can also optimize the manufacturing, sell you primary and ancillary equipment, commission, service and maintain it also.

If the world’s largest defense, space and aviation companies trust us with their critical projects, then you can have confidence in choosing us too.

When it comes to metal 3D printing, we are backed by the world's largest additive manufacturing R&D, MCAM. We are co-located with 50+ fulltime researchers and technical staff who specialize in making metal 3D printing better.
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We provide world-leading aviation, space, defense, automotive and tooling companies with solutions for their complex applications.

If you have any other questions, contact us here.