Wipro 3D specialises in variety of metals and alloys such as titanium, stainless steel, aluminum, Inconel, copper and cobalt-chrome alloys. There are many custom alloys which Wipro 3D has developed to meet their specific functional requirements from the customers. In conversation with Sanskriti Ramachandran, Yathiraj Kasal, General Manager & Business Head, Wipro 3D delves into the unknown 3D metal printing process and its technicalities.

What key sectors are you focusing on for your metal 3D printing services?

Wipro 3D primarily focus on the aerospace, automotive, energy, medical, and industrial manufacturing sectors. We cater to prototyping, tooling and production needs of our customers. Our customers benefit greatly from faster turnaround time, tool less production, cost efficiency, and supply chain efficiency, that metal 3D printing offers. Apart from metal 3D printing Wipro 3D also provides polymer 3D printing services.

What types of metals and alloys do you specialise in for metal 3D printing?

Wipro 3D specialises in variety of metals and alloys such as titanium, stainless steel, aluminum, Inconel, copper and cobalt-chrome alloys. There are many custom alloys which Wipro 3D has developed to meet their specific functional requirements from the customers.

How do you incorporate new materials or technology into your manufacturing processes?

We stay at the forefront of the materials by continuously researching and integrating new materials and cutting-edge technologies into our manufacturing processes. This includes collaborating with material scientists, engaging with customers to understand new requirements, and leveraging advanced software for design optimisation. We have consistently introduced many difficult to print materials successfully with our strong material and manufacturing expertise.

Share a success story where 3D metal printing significantly benefited a client’s project.

We take pride in collaborating on numerous success stories with our valued customers, one of which is the AM PS4 engine for ISRO's LPSC unit. This engine powers the upper stage of the PSLV. LPSC redesigned it with the Design for Additive Manufacturing (DfAM) approach, achieving significant advantages. Using the Laser Powder Bed Fusion technique, the number of parts was reduced from 14 to a single piece, eliminating 19 weld joints. This streamlined process drastically cut raw material usage, requiring just 13.7 kg of metal powder compared to 565 kg of forgings and sheets in the conventional method. It also reduced overall production time by 60 per cent. The engine underwent successful hot testing at ISRO Propulsion Complex, Mahendragiri, in May 2024, marking a milestone in efficient and innovative manufacturing.

What are your company’s goals for expanding or enhancing its 3D metal printing capabilities?

Our goals include expanding our production capacity, investing in new machinery bring out new machines, and enhancing our R&D capabilities. We aim to explore new markets and applications for 3D metal printing, as well as improve our service offerings to provide even greater value to our clients.

What do you believe will be the next big breakthrough in 3D metal printing that could reshape manufacturing?

We believe that the next big breakthrough will be the development of fully automated, end-to-end 3D metal printing systems. These systems will integrate design, printing, and post-processing in a seamless workflow, significantly reducing production times and costs while maintaining high-quality standards. This advancement has the potential to revolutionise the manufacturing landscape.