[{"data":1,"prerenderedAt":869},["ShallowReactive",2],{"ticker-data":3,"story-article/3d-printing-casts-new-dimension-on-metals":550},[4,52,82,112,148,186,229,261,297,336,378,419,460,490,520],{"publishedDate":5,"updateFrequency":6,"updateFrequencyText":7,"label":8,"today":9,"last":10,"percentageChange":11,"yearToDate":12,"yearOnYear":13,"oneYearIndexTrend":14,"url":48,"subscription":49,"isProtected":50,"hasAccess":51},"2026-10-14","2wk","Updated every 2 weeks","Lithium",317.07,322.34,-1.64,35.66,90.62,[15,16,18,21,24,27,30,33,36,39,42,45],{"date":5,"value":9},{"date":17,"value":10},"2026-09-30",{"date":19,"value":20},"2026-09-16",354.99,{"date":22,"value":23},"2026-09-02",385.07,{"date":25,"value":26},"2026-08-19",372.67,{"date":28,"value":29},"2026-08-05",367.54,{"date":31,"value":32},"2026-07-22",388.26,{"date":34,"value":35},"2026-07-08",399.4,{"date":37,"value":38},"2026-06-24",410.62,{"date":40,"value":41},"2026-06-10",427.77,{"date":43,"value":44},"2026-05-27",449.85,{"date":46,"value":47},"2026-05-13",451.12,"/lithium/prices",null,false,true,{"publishedDate":5,"updateFrequency":6,"updateFrequencyText":7,"label":53,"today":54,"last":55,"percentageChange":56,"yearToDate":57,"yearOnYear":58,"oneYearIndexTrend":59,"url":48,"subscription":49,"isProtected":50,"hasAccess":51},"Lithium Carbonate",256.83,278.71,-7.85,1.12,46.89,[60,61,62,64,66,68,70,72,74,76,78,80],{"date":5,"value":54},{"date":17,"value":55},{"date":19,"value":63},300.39,{"date":22,"value":65},306.07,{"date":25,"value":67},297.22,{"date":28,"value":69},296.63,{"date":31,"value":71},309.38,{"date":34,"value":73},317.2,{"date":37,"value":75},330.54,{"date":40,"value":77},346.5,{"date":43,"value":79},358.35,{"date":46,"value":81},350.28,{"publishedDate":5,"updateFrequency":6,"updateFrequencyText":7,"label":83,"today":84,"last":85,"percentageChange":86,"yearToDate":87,"yearOnYear":88,"oneYearIndexTrend":89,"url":48,"subscription":49,"isProtected":50,"hasAccess":51},"Lithium Hydroxide",292.05,311.1,-6.12,43.7,92,[90,91,92,94,96,98,100,102,104,106,108,110],{"date":5,"value":84},{"date":17,"value":85},{"date":19,"value":93},339.85,{"date":22,"value":95},352.45,{"date":25,"value":97},341.12,{"date":28,"value":99},337.87,{"date":31,"value":101},354.36,{"date":34,"value":103},364.06,{"date":37,"value":105},376.67,{"date":40,"value":107},393.29,{"date":43,"value":109},411.01,{"date":46,"value":111},408.51,{"publishedDate":5,"updateFrequency":113,"updateFrequencyText":114,"label":115,"today":116,"last":117,"percentageChange":118,"yearToDate":119,"yearOnYear":120,"oneYearIndexTrend":121,"url":147,"subscription":49,"isProtected":50,"hasAccess":51},"1wk","Updated every week","Cobalt",171.41,173.83,-1.39,-27.13,-1.06,[122,123,125,126,129,131,133,136,138,141,142,145],{"date":5,"value":116},{"date":124,"value":117},"2026-10-07",{"date":17,"value":117},{"date":127,"value":128},"2026-09-23",175.44,{"date":19,"value":130},178.66,{"date":22,"value":132},189.92,{"date":134,"value":135},"2026-08-26",192.6,{"date":25,"value":137},199.83,{"date":139,"value":140},"2026-08-12",217.25,{"date":28,"value":140},{"date":143,"value":144},"2026-07-29",221.25,{"date":31,"value":146},224.44,"/cobalt/prices",{"publishedDate":149,"updateFrequency":6,"updateFrequencyText":7,"label":150,"today":151,"last":152,"percentageChange":153,"yearToDate":154,"yearOnYear":155,"oneYearIndexTrend":156,"url":185,"subscription":49,"isProtected":50,"hasAccess":51},"2026-10-21","Nickel",107.13,114.04,-6.06,-11.27,-0.65,[157,158,159,161,164,166,168,170,173,176,179,182],{"date":149,"value":151},{"date":124,"value":152},{"date":127,"value":160},116.1,{"date":162,"value":163},"2026-09-09",119.13,{"date":134,"value":165},119.61,{"date":139,"value":167},121.04,{"date":143,"value":169},121.19,{"date":171,"value":172},"2026-07-15",122.66,{"date":174,"value":175},"2026-07-01",125.61,{"date":177,"value":178},"2026-06-17",131.5,{"date":180,"value":181},"2026-06-03",134.65,{"date":183,"value":184},"2026-05-20",135.83,"/nickel/prices",{"publishedDate":17,"updateFrequency":187,"updateFrequencyText":188,"label":189,"today":190,"last":191,"percentageChange":192,"yearToDate":193,"yearOnYear":194,"oneYearIndexTrend":195,"url":228,"subscription":49,"isProtected":50,"hasAccess":51},"1mo","Updated every month","Natural Graphite",78.45,80.18,-2.16,-3.84,-4.03,[196,197,199,202,205,208,211,214,217,220,223,226],{"date":17,"value":190},{"date":198,"value":191},"2026-08-28",{"date":200,"value":201},"2026-07-31",80.66,{"date":203,"value":204},"2026-06-30",82.87,{"date":206,"value":207},"2026-05-29",82.99,{"date":209,"value":210},"2026-04-30",82.93,{"date":212,"value":213},"2026-03-31",82.39,{"date":215,"value":216},"2026-02-27",81.92,{"date":218,"value":219},"2026-01-30",81.69,{"date":221,"value":222},"2025-12-31",81.58,{"date":224,"value":225},"2025-11-28",81.35,{"date":227,"value":225},"2025-10-31","/natural-graphite/prices",{"publishedDate":17,"updateFrequency":187,"updateFrequencyText":188,"label":230,"today":231,"last":232,"percentageChange":233,"yearToDate":234,"yearOnYear":235,"oneYearIndexTrend":236,"url":260,"subscription":49,"isProtected":50,"hasAccess":51},"Anode Coke",86.15,81.86,5.24,15.73,19.78,[237,238,239,241,242,244,246,248,250,252,254,257],{"date":17,"value":231},{"date":200,"value":232},{"date":203,"value":240},80.54,{"date":206,"value":240},{"date":209,"value":243},84.01,{"date":212,"value":245},79.79,{"date":215,"value":247},75.72,{"date":218,"value":249},74.61,{"date":221,"value":251},74.44,{"date":227,"value":253},72.75,{"date":255,"value":256},"2025-09-30",71.92,{"date":258,"value":259},"2025-08-29",71.46,"/synthetic-graphite/prices",{"publishedDate":262,"updateFrequency":187,"updateFrequencyText":188,"label":263,"today":264,"last":265,"percentageChange":266,"yearToDate":267,"yearOnYear":268,"oneYearIndexTrend":269,"url":296,"subscription":49,"isProtected":50,"hasAccess":51},"2026-10-15","Anode",80.45,80.24,0.27,1.81,3.2,[270,271,273,275,276,278,281,284,287,289,291,293],{"date":262,"value":264},{"date":272,"value":265},"2026-09-15",{"date":274,"value":265},"2026-08-17",{"date":171,"value":265},{"date":277,"value":265},"2026-06-15",{"date":279,"value":280},"2026-05-15",79.16,{"date":282,"value":283},"2026-04-15",81.98,{"date":285,"value":286},"2026-03-16",79.03,{"date":288,"value":286},"2026-02-16",{"date":290,"value":286},"2026-01-15",{"date":292,"value":286},"2025-12-15",{"date":294,"value":295},"2025-11-17",77.79,"/anode/prices",{"publishedDate":298,"updateFrequency":187,"updateFrequencyText":188,"label":299,"today":300,"last":301,"percentageChange":302,"yearToDate":303,"yearOnYear":304,"oneYearIndexTrend":305,"url":335,"subscription":49,"isProtected":50,"hasAccess":51},"2026-08-01","Cathode",73.32,77.21,-5.04,14.41,55.07,[306,307,308,311,314,317,320,323,325,327,329,332],{"date":298,"value":300},{"date":174,"value":301},{"date":309,"value":310},"2026-06-01",80.32,{"date":312,"value":313},"2026-05-01",81.71,{"date":315,"value":316},"2026-04-01",77.27,{"date":318,"value":319},"2026-03-01",81.99,{"date":321,"value":322},"2026-02-01",80.5,{"date":290,"value":324},72.79,{"date":292,"value":326},64.08,{"date":294,"value":328},62.01,{"date":330,"value":331},"2025-10-15",53.51,{"date":333,"value":334},"2025-09-15",49.5,"/cathode/prices",{"publishedDate":337,"updateFrequency":187,"updateFrequencyText":188,"label":338,"today":339,"last":340,"percentageChange":341,"yearToDate":342,"yearOnYear":343,"oneYearIndexTrend":344,"url":377,"subscription":49,"isProtected":50,"hasAccess":51},"2025-03-31","Lithium ion Batteries",74.53,71.3,4.53,-1.6,-20.88,[345,346,348,351,354,357,360,363,366,368,371,374],{"date":337,"value":339},{"date":347,"value":340},"2025-02-28",{"date":349,"value":350},"2025-01-31",71.45,{"date":352,"value":353},"2024-12-31",75.74,{"date":355,"value":356},"2024-11-29",76.98,{"date":358,"value":359},"2024-10-31",77.34,{"date":361,"value":362},"2024-09-30",77.43,{"date":364,"value":365},"2024-08-30",80.56,{"date":367,"value":207},"2024-07-31",{"date":369,"value":370},"2024-06-28",87.2,{"date":372,"value":373},"2024-05-31",90.7,{"date":375,"value":376},"2024-04-30",93.2,"/battery-gigafactory/prices",{"publishedDate":379,"updateFrequency":6,"updateFrequencyText":7,"label":380,"today":381,"last":382,"percentageChange":383,"yearToDate":384,"yearOnYear":385,"oneYearIndexTrend":386,"url":418,"subscription":49,"isProtected":50,"hasAccess":51},"2026-10-08","Black Mass",37.11,38.95,-4.72,-14,18.31,[387,388,390,393,396,399,402,405,408,411,414,416],{"date":379,"value":381},{"date":389,"value":382},"2026-09-24",{"date":391,"value":392},"2026-09-10",42.03,{"date":394,"value":395},"2026-08-27",43.88,{"date":397,"value":398},"2026-08-13",42.33,{"date":400,"value":401},"2026-07-30",43.42,{"date":403,"value":404},"2026-07-16",46.74,{"date":406,"value":407},"2026-07-02",46.01,{"date":409,"value":410},"2026-06-18",49.57,{"date":412,"value":413},"2026-02-12",47.34,{"date":415,"value":410},"2026-01-29",{"date":290,"value":417},43.15,"/recycling/black-mass-prices",{"publishedDate":262,"updateFrequency":187,"updateFrequencyText":188,"label":420,"today":421,"last":422,"percentageChange":423,"yearToDate":424,"yearOnYear":425,"oneYearIndexTrend":426,"url":459,"subscription":49,"isProtected":50,"hasAccess":51},"Rare Earths",172.08,171.72,0.21,20.59,30.21,[427,428,430,433,436,439,442,445,448,451,454,457],{"date":262,"value":421},{"date":429,"value":422},"2026-10-01",{"date":431,"value":432},"2026-09-03",170.83,{"date":434,"value":435},"2026-08-20",169.63,{"date":437,"value":438},"2026-08-06",172.28,{"date":440,"value":441},"2026-07-23",173.94,{"date":443,"value":444},"2026-07-09",171.69,{"date":446,"value":447},"2026-06-25",168.55,{"date":449,"value":450},"2026-06-11",165,{"date":452,"value":453},"2026-05-28",163.89,{"date":455,"value":456},"2026-05-14",172.63,{"date":209,"value":458},175.6,"/rare-earths/prices",{"publishedDate":198,"updateFrequency":187,"updateFrequencyText":188,"label":461,"today":462,"last":463,"percentageChange":464,"yearToDate":465,"yearOnYear":466,"oneYearIndexTrend":467,"url":377,"subscription":49,"isProtected":50,"hasAccess":51},"NCM Mid-Nickel",152.7,162.48,-6.02,17.38,53.11,[468,469,470,472,474,476,478,480,482,484,486,488],{"date":198,"value":462},{"date":200,"value":463},{"date":203,"value":471},171.08,{"date":206,"value":473},173.65,{"date":209,"value":475},164.53,{"date":212,"value":477},157.28,{"date":215,"value":479},151.44,{"date":218,"value":481},144.5,{"date":221,"value":483},130.09,{"date":224,"value":485},124.6,{"date":227,"value":487},122.35,{"date":255,"value":489},103.5,{"publishedDate":198,"updateFrequency":187,"updateFrequencyText":188,"label":491,"today":492,"last":493,"percentageChange":494,"yearToDate":495,"yearOnYear":496,"oneYearIndexTrend":497,"url":377,"subscription":49,"isProtected":50,"hasAccess":51},"NCM High-Nickel",144.45,149.67,-3.49,26.69,49.06,[498,499,500,502,504,506,508,510,512,514,516,518],{"date":198,"value":492},{"date":200,"value":493},{"date":203,"value":501},157.37,{"date":206,"value":503},160,{"date":209,"value":505},149.53,{"date":212,"value":507},141.97,{"date":215,"value":509},136.99,{"date":218,"value":511},129.81,{"date":221,"value":513},114.02,{"date":224,"value":515},109.17,{"date":227,"value":517},109.02,{"date":255,"value":519},99.44,{"publishedDate":198,"updateFrequency":187,"updateFrequencyText":188,"label":521,"today":522,"last":523,"percentageChange":524,"yearToDate":525,"yearOnYear":526,"oneYearIndexTrend":527,"url":377,"subscription":49,"isProtected":50,"hasAccess":51},"LFP",229.17,218.34,4.96,49.35,83.44,[528,529,530,532,534,536,538,540,542,544,546,548],{"date":198,"value":522},{"date":200,"value":523},{"date":203,"value":531},239.1,{"date":206,"value":533},258.32,{"date":209,"value":535},239.37,{"date":212,"value":537},213.01,{"date":215,"value":539},204.49,{"date":218,"value":541},218.06,{"date":221,"value":543},153.45,{"date":224,"value":545},134.02,{"date":227,"value":547},118.22,{"date":255,"value":549},111.93,{"id":551,"uuid":552,"name":553,"slug":554,"full_slug":555,"content":556,"relatedArticles":867,"relatedVideos":868},112475020444182,"abdf5c6e-fa07-4864-9418-e4246aefd991","3D printing casts new dimension on metals","3d-printing-casts-new-dimension-on-metals","article/3d-printing-casts-new-dimension-on-metals",{"_uid":557,"date":558,"tags":559,"editor":560,"content":570,"excerpt":845,"featured":50,"reporter":846,"_editable":850,"component":851,"seo_title":553,"categories":852,"visibility":859,"author_company":49,"featured_image":860,"seo_description":845,"author_full_name":49,"author_job_title":49,"formattedDate":865,"formattedArticleDate":866},"704b541e-021c-444c-b17e-9dae12bacd92","2016-07-20 00:00",[],[561],{"slug":562,"name":563,"content":564},"didi-bostock","Didi Bostock",{"job_title":565,"image":566,"bio":568,"linkedin":569},"Editor - Energy Transition & Economics",{"filename":567},"https://a.storyblok.com/f/287943243085208/512x512/2c5ca5c1a3/didi-bostock.jpeg","Didi is the Energy Transition & Economics Editor at Benchmark, covering a broad range of markets across the energy transition. His remit spans from downstream sectors such as BESS and EVs, through to midstream such as new technologies and battery production, to upstream critical minerals mining. He also leads on financial analysis across these supply chains, alongside in-depth policy analysis.\n","https://www.linkedin.com/in/didi-bostock-656342198/",{"type":571,"content":572},"doc",[573,580,585,590,595,600,605,610,615,620,625,630,635,640,645,650,657,662,667,672,677,680,683,688,693,698,703,706,711,716,721,724,729,734,739,744,749,754,759,764,769,772,777,782,787,792,797,802,807,812,817,822,827,832,835,840],{"type":574,"attrs":575,"content":576},"paragraph",{"textAlign":49},[577],{"text":578,"type":579}," Aerospace and hi-tech goods are driving the adoption of 3D printing in the industrial metalcasting sector. The impact of the new way to produce metal shapes is set to lead to more complex, customised and lower cost metal parts. Jessica Roberts, Senior Analyst at Roskill Information Services, analyses the disruption caused by the rise of 3D printing in the global foundry industry","text",{"type":574,"attrs":581,"content":582},{"textAlign":49},[583],{"text":584,"type":579},"The metalcasting industry is integral to modern life. From the cars we drive, airplanes we fly in, and utility pipes that keep our cities running – all would not be possible if it was not for the ability to cast metal into a variety of different shapes.",{"type":574,"attrs":586,"content":587},{"textAlign":49},[588],{"text":589,"type":579},"But the way we produce complex metal shapes is changing.",{"type":574,"attrs":591,"content":592},{"textAlign":49},[593],{"text":594,"type":579},"Until very recently, it was the case that almost all complex shapes were produced only by metalcasting or fabrication. But the rise of 3D printing has offered a new, cheaper way to produce some shapes in a quicker and more complex fashion. And this new technology is sparking unexpected change in the traditional casting industry that has fundamentally been the same for hundreds of years.",{"type":574,"attrs":596,"content":597},{"textAlign":49},[598],{"text":599,"type":579},"Around 90% of all goods manufactured in the US contain metal cast products according to The American Foundry Society (AFS) and have contributed to a huge global industry that was worth $300bn in 2014.",{"type":574,"attrs":601,"content":602},{"textAlign":49},[603],{"text":604,"type":579},"Unsurprisingly, in volume terms, China is the world’s leading producer accounting for 45% of total tonnages produced, a figure The China Foundry Association expects to reach 50m tonnes and $120bn by the end of this year.",{"type":574,"attrs":606,"content":607},{"textAlign":49},[608],{"text":609,"type":579},"The second largest producer of castings is Europe, accounting for 15% of output by volume at a value of €41.3bn ($46bn) in 2014, according to the European Foundry Association (CAEF).",{"type":574,"attrs":611,"content":612},{"textAlign":49},[613],{"text":614,"type":579},"The USA accounts for around 13% of casting output by volume and the AFS forecasts the US market will reach a value of $37.5bn in 2015.",{"type":574,"attrs":616,"content":617},{"textAlign":49},[618],{"text":619,"type":579},"World castings output grew to 107m tonnes in 2014, according to estimates by UK-based Roskill Information Services, representing a CAGR of 4% between 2010 and 2014. The bulk of castings produced are made of ferrous metals at 85m tonnes in 2013, comprising mainly grey iron and ductile iron. The non-ferrous casting sector is much smaller, amounting to 18.3m tonnes in 2013 and dominated by aluminium at over 15.4m tonnes.",{"type":574,"attrs":621,"content":622},{"textAlign":49},[623],{"text":624,"type":579},"In the past decade nearly all growth in castings output has occurred in Asia, which has been to the detriment of established foundries in Western Europe and North America. This has occurred because of the growth in motor vehicle production in Asian countries, particularly China.",{"type":574,"attrs":626,"content":627},{"textAlign":49},[628],{"text":629,"type":579},"After automotive markets (25% of the total), most Chinese castings serve industrial applications. Internal combustion engines account for around 14% of China’s metal casting output, followed by heavy and mining machinery (12%), casting pipe and fitting (11%), and construction machinery (10%).",{"type":574,"attrs":631,"content":632},{"textAlign":49},[633],{"text":634,"type":579},"In order to compete, established foundries in western countries have become increasingly streamlined and efficient.",{"type":574,"attrs":636,"content":637},{"textAlign":49},[638],{"text":639,"type":579},"The average output of castings for each employee in Europe has increased steadily in recent years; in ferrous casting it rose from 55 tonnes per person in 2010 to 70 tonnes per person in 2013 – with a range of up to 120 tonnes. By comparison, China’s 2m employees in the metal casting sector produced an average of 20 tonnes of castings per person in 2012.",{"type":574,"attrs":641,"content":642},{"textAlign":49},[643],{"text":644,"type":579},"Most metalcasting is of high-bulk and relatively simple goods, but some niche applications offer opportunities to produce high-tech parts – such as wind turbine blades, aerospace parts and intricate consumer goods like golf club heads.",{"type":574,"attrs":646,"content":647},{"textAlign":49},[648],{"text":649,"type":579},"It is into this competitive space that an alternative manufacturing method is starting to emerge.",{"type":651,"attrs":652,"content":654},"heading",{"level":653,"textAlign":49},3,[655],{"text":656,"type":579}," Rise of 3D printing",{"type":574,"attrs":658,"content":659},{"textAlign":49},[660],{"text":661,"type":579},"Additive manufacturing, or 3D printing, is the creation of three-dimensional objects layer by layer.",{"type":574,"attrs":663,"content":664},{"textAlign":49},[665],{"text":666,"type":579},"The design for the part is read by the printer from a digital computer aided design (CAD) file. Parts are constructed from a high number of two-dimensional layers, built up vertically. There are a number of different printing technologies available, depending on the type of printing material used.",{"type":574,"attrs":668,"content":669},{"textAlign":49},[670],{"text":671,"type":579},"Metal-based systems include:",{"type":574,"attrs":673,"content":674},{"textAlign":49},[675],{"text":676,"type":579},"These technologies are compatible with a number of different metals such as stainless steel, cobalt-chrome, titanium, nickel-chrome, tool steel, aluminium, gold, silver and others. Not all technologies are compatible with each of the metals.",{"type":574,"attrs":678,"content":679},{"textAlign":49},[],{"type":574,"attrs":681,"content":682},{"textAlign":49},[],{"type":574,"attrs":684,"content":685},{"textAlign":49},[686],{"text":687,"type":579},"The manufacturing principle of these technologies is similar, in that an electron beam or laser is used to melt a layer of metal powder into the desired geometry. Another layer of metal powder is deposited on top and melted, and the process is repeated until the part is complete.",{"type":574,"attrs":689,"content":690},{"textAlign":49},[691],{"text":692,"type":579},"The part then undergoes any postproduction processing that is required. Build time and materials used differ depending on the technology – for example electron beam welding has a build speed of around 60cm3 per hour, compared to 32.4cm3 per hour for direct metal laser sintering.",{"type":574,"attrs":694,"content":695},{"textAlign":49},[696],{"text":697,"type":579},"Polymer-based printing systems include:",{"type":574,"attrs":699,"content":700},{"textAlign":49},[701],{"text":702,"type":579},"Materials for use with polymer printers include epoxy-based materials, nylon, ABS, wax and polystyrene – but, as with metal-based systems, not all materials are compatible with each process.",{"type":574,"attrs":704,"content":705},{"textAlign":49},[],{"type":574,"attrs":707,"content":708},{"textAlign":49},[709],{"text":710,"type":579},"Stereolithography is the building of a part layer by layer, through the use of an ultraviolet laser to solidify liquid photopolymer resins. Fused deposition modelling creates parts through layers of engineering-grade thermoplastics. Thermoplastic filament is heated up and extruded through the 3D printer. As in the metal additive manufacturing processes, selective laser sintering can be used with polymer systems when a polymer powder layer is deposited and melted by the laser into the desired geometry. This is carried out repeatedly until the part is complete.",{"type":574,"attrs":712,"content":713},{"textAlign":49},[714],{"text":715,"type":579},"Most recently, high-speed sintering (HSS) has been developed by Sheffield University in the UK as a possible competitor to injection moulding. HSS prints infra-red absorbing ink onto a powder bed. After a layer is printed, it is exposed to infrared light which selectively causes the inkcovered powder to fuse. German 3D printer manufacturer Voxeljet is aiming to have commercial HSS printers for sale by 2018.",{"type":574,"attrs":717,"content":718},{"textAlign":49},[719],{"text":720,"type":579},"Additive manufacturing has been around since the 1980s but technological advances in the last ten years have enabled the process to be used commercially.",{"type":574,"attrs":722,"content":723},{"textAlign":49},[],{"type":574,"attrs":725,"content":726},{"textAlign":49},[727],{"text":728,"type":579},"According to a May 2015 study carried out by SMS Research Advisors with additive manufacturing professionals, the top five industries for 3D printing are consumer products (26%), medical (15%), aerospace (11%), automotive (8%), and energy (6%), with 34% of products serving other industries.",{"type":574,"attrs":730,"content":731},{"textAlign":49},[732],{"text":733,"type":579},"Although still fairly niche, the industry is growing rapidly and was reported to have increased by 35% between 2013 and 2014 to reach US$4.1Bn, according to the US consultancy Wohlers Associates.",{"type":574,"attrs":735,"content":736},{"textAlign":49},[737],{"text":738,"type":579},"3D printing offers several benefits compared to conventional manufacturing methods, such as metalcasting or subtractive technologies (i.e. where tooling is required).",{"type":574,"attrs":740,"content":741},{"textAlign":49},[742],{"text":743,"type":579},"These are mainly focused on product complexity and product customisation.",{"type":574,"attrs":745,"content":746},{"textAlign":49},[747],{"text":748,"type":579},"In conventional manufacturing, it is generally true that as either complexity or customisation increases, so too does the product cost and production time.",{"type":574,"attrs":750,"content":751},{"textAlign":49},[752],{"text":753,"type":579},"For example, a tailor-made prosthesis for an amputee is likely to be a one-off product that traditionally would be expensive and have a long lead time. Now it is possible to design and 3D print individual prosthetics or implants – once a personalised CAD file has been created – in a matter of days.",{"type":574,"attrs":755,"content":756},{"textAlign":49},[757],{"text":758,"type":579},"Participants in the SMS Research Advisors study listed the top four benefits of additive manufacturing as being:",{"type":574,"attrs":760,"content":761},{"textAlign":49},[762],{"text":763,"type":579},"Aerospace and medical applications have been early adopters of additive manufacturing technology, and the CEO of 3D printer maker Stratasys believes that within 10 years every commercial airplane will have 3D printed parts on it.",{"type":574,"attrs":765,"content":766},{"textAlign":49},[767],{"text":768,"type":579},"Additive manufacturing technology provider 3T RPD Ltd reported that it had printed a fuel injector made of Inconel 718 (austenite nickelchrome superalloy), 600mm by 160mm in size with a layer thickness of 40μm.",{"type":574,"attrs":770,"content":771},{"textAlign":49},[],{"type":574,"attrs":773,"content":774},{"textAlign":49},[775],{"text":776,"type":579},"The part was printed using direct metal laser sintering technology and had a build time of 50 hours and a finishing time of three hours. The fuel injector cost around £3,500 per unit ($5,470) and was printed as one part, when previously it had comprised eight parts when made via traditional methods.",{"type":574,"attrs":778,"content":779},{"textAlign":49},[780],{"text":781,"type":579},"However, 3D printing does not always take away market share from metalcasting.",{"type":574,"attrs":783,"content":784},{"textAlign":49},[785],{"text":786,"type":579},"German printer developer Voxeljet has demonstrated that it can print with silica sand for making cores used in standard sand casting, and has also successfully printed polymethyl methacrylate (PMMA) parts for use in investment casting. In the standard investment casting process an expendable wax model of the shape to be cast is dipped into a thin refractory slurry and then coated with a primary refractory coating or stucco.",{"type":574,"attrs":788,"content":789},{"textAlign":49},[790],{"text":791,"type":579},"This is repeated several times until a refractory or ceramic shell has been built up.",{"type":574,"attrs":793,"content":794},{"textAlign":49},[795],{"text":796,"type":579},"The pattern is then heated to remove the wax after which molten metal can be added to form the casting.",{"type":574,"attrs":798,"content":799},{"textAlign":49},[800],{"text":801,"type":579},"Instead of using wax, Voxeljet prints a very precise PMMA model of the shape to be cast which is then used in the same manner as wax in investment casting. Therefore additive manufacturing could actually enhance and work in partnership with standard metalcasting methods.",{"type":651,"attrs":803,"content":804},{"level":653,"textAlign":49},[805],{"text":806,"type":579}," Outlook for 3D printing",{"type":574,"attrs":808,"content":809},{"textAlign":49},[810],{"text":811,"type":579},"While additive manufacturing offers many positives in terms of producing customised and complex parts, it is not without its drawbacks.",{"type":574,"attrs":813,"content":814},{"textAlign":49},[815],{"text":816,"type":579},"In the SMS Research Advisors study, respondents listed their main four challenges as being: equipment costs, limited materials, post-processing requirements, and manufacturing costs.",{"type":574,"attrs":818,"content":819},{"textAlign":49},[820],{"text":821,"type":579},"The affordability and speed of 3D printing is improving as new designs are brought out and patents expire. Yet for bulk production of simple parts, 3D printing is much more expensive and slower than traditional manufacturing methods like metalcasting and injection moulding.",{"type":574,"attrs":823,"content":824},{"textAlign":49},[825],{"text":826,"type":579},"Because of these challenges, additive manufacturing is unlikely to take significant market share from traditional manufacturing in the medium-term. However the technology can be a lower cost and quicker alternative in some applications, particularly in production of niche and high-value goods.",{"type":574,"attrs":828,"content":829},{"textAlign":49},[830],{"text":831,"type":579},"3D printing can also be used in conjunction with metalcasting to improve final parts.",{"type":574,"attrs":833,"content":834},{"textAlign":49},[],{"type":574,"attrs":836,"content":837},{"textAlign":49},[838],{"text":839,"type":579},"Stratasys expects that additive metal use will double in size between 2015 and 2018. US consultancy Wohlers Associates, meanwhile, forecasts an overall industry growth of 15%py to 2020 to reach $9.5Bn.",{"type":574,"attrs":841,"content":842},{"textAlign":49},[843],{"text":844,"type":579},"Compared to the US$300Bn metalcasting sector, this is clearly still a niche industry, but it does appear to offer good opportunities to the high-tech sector and to the specialist metal powders and polymers used in 3D printing.","Aerospace and hi-tech goods are driving the adoption of 3D printing in the industrial metalcasting sector. The impact of the new way to produce metal shapes is set to lead to more complex, customised and lower cost metal parts. Jessica Roberts, Senior Analyst at Roskill Information Services, analyses the disruption caused by the rise of 3D printing in the global foundry industry",[847],{"slug":562,"name":563,"content":848},{"job_title":565,"image":849,"bio":568,"linkedin":569},{"filename":567},"\u003C!--#storyblok#{\"name\": \"article\", \"space\": \"\", \"uid\": \"704b541e-021c-444c-b17e-9dae12bacd92\", \"id\": \"\"}-->","article",[853,856],{"slug":854,"name":855},"batteries","Batteries",{"slug":857,"name":858},"critical-minerals","Critical Minerals","private",{"id":49,"alt":861,"name":861,"focus":861,"title":861,"source":861,"filename":862,"copyright":861,"fieldtype":863,"meta_data":864,"is_external_url":51},"","https://a.storyblok.com/f/287943243085208/b45d568073/bm-screen-shot-2016-07-20-at-181805.png","asset",{"alt":861,"title":861,"source":861,"copyright":861},"Jul 20, 2016","20th July 2016",[],[],1792773948956]