Aerosint completed the SME instrument Phase I study in order to validate the market interest and initial technical feasibility of its selective powder deposition system for enabling waste-free or multi-material AM. Having already demonstrated that two separate powder materials could be co-deposited in a single layer, the next technical step to demonstrate feasibility was to test material co-consolidation after powder deposition in a relevant machine environment. We showed that co-sintering of polymers of different colors and rigidities is possible at a basic level. For metals, we collaborated with the Fraunhofer IGCV research institute, which has demonstrated previous success in co-processing of steel and copper alloy in a single part. There is thus a very high chance that metals deposited with Aerosint’s system can be fully co-consolidated into a single part. Work is also under way at Aerosint to demonstrate binder-free and waste-free ceramic, multi-ceramic, and ceramic-metal part fabrication.
Through market research and direct conversations with potential end users, we have validated the market opportunity for selective powder deposition as applied to AM. The research indicates that the additive manufacturing market is growing quickly with a current estimated growth rate of 12.5% per year. Companies using AM are increasingly interested in metal materials and using AM methods for small series production in addition to prototyping. The clear goal is accelerated product development leading manufacturing. We have validated that material waste cost in industrial polymer AM is a large pain point for service bureaus, and it inhibits the processing of high performance polymers. Multi-material AM is currently an almost non-existent market, but conversations with industry players indicate real interest for multi-material parts, especially in sectors like aerospace, soft robotics, and medical prostheses.
Our findings justify further development of selective powder deposition technology, both for material savings and multi-material applications. In the short term these developments will be made in cooperation with research centers and other SMEs with specific need for Aerosint’s technology. In the longer term, our go-to-market strategy will likely involve co-development with a major OEM of LPBF system to leverage their machine-building expertise and existing sales and distribution channels.
