Researchers Develop High-Strength Aluminum Wire Feedstock for 3D Printing

The Innovative Manufacturing Cooperative Research Center (IMCRC) and ASX-listed metal additive manufacturing company AML3D have concluded their research and development (R&D) project with the commercialization of a high-strength aluminum wire feedstock for welding and 3D printing applications. Further work will be undertaken by AML3D, including testing to industry standards, as they work toward commercialization.

Developed in collaboration with Deakin University’s Institute for Frontier Materials (IFM), the researchers say the wire can transform the way complex metal objects are manufactured.

Commencing in 2021, the project was born from AML3D’s need for a high-strength aluminum welding wire to use in 3D printing that required minimal or no heat treatment post-manufacture.

“Our patented Wire Additive Manufacturing (WAM) 3D metal printing process can produce medium-to-large objects. However, the aluminum alloys we currently use require up to 24 hours of heat treatment to reach optimum strength, which can be costly and creates some logistical challenges,” says Andy Sales, ALM3D’s executive director and chief technical officer.

“Through our partnership with IFM and IMCRC, we’ve developed a cost-effective, high-strength aluminum alloy wire that requires just 30 minutes of heat treatment once printed. When used with our WAM technology, this wire has the potential to create additional applications across industries like shipbuilding and aviation further disrupting traditional manufacturing processes,” Sales adds. “By supporting the project and facilitating the introduction to IFM, IMCRC has helped change the trajectory of our business, expanding our potential customer base and creating further opportunities to innovate through R&D.”

According to IFM, this project encompassed more than 20 different compositions and iterations. “Our chosen alloy, a mixture of aluminum, magnesium and scandium, has recently been patented, and we’ve also commenced commercial production,” says Thomas Dorin, IFM senior research fellow. “The project's next phase involves printing products to demonstrate the wire’s potential applications. We’ll then work with AML3D to show shipbuilders how they can print directly at the shipyard, which is an effective way to reduce material waste and streamline logistics.”

IMCRC is pleased the project outcomes have solved a real-world challenge for AML3D and the 3D printing industry. “By creating an alternative to traditional processes like subtractive manufacturing, AML3D has the potential to catalyze a step change for industry and encourage the adoption of more innovative manufacturing techniques,” says David Chuter, IMCRC’s CEO and managing director. “Making the manufacture of metal parts more efficient, cost-effective and timely is critical to helping Australia’s manufacturing sector become more competitive and attractive, which will encourage customers to bring production onshore.”

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