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Rare crystal shapes yield stronger 3D-printed metal parts
Industry News- Oct 01,25
Quasicrystals, which were previously considered a myth, are now replicable for large-scale industrial applications. Stakeholders must support investments in 3D printing technologies and continued research into these crystal structures, says Emily Newton.
Experts from the National Institute of Standards and Technology (NIST) have uncovered structural differences between 3D-printed and conventional aluminum alloys. The discovery revealed how a rare crystal structure enhances 3D-printed metal strength, giving industrial workers a new, stronger material to leverage.
Relationship between quasicrystals and 3d-printed metal strength
In 2011, Dan Shechtman won the Nobel Prize in Chemistry for his discovery of a rare crystal structure that scientists believed to be impossible. Dubbed quasicrystals, these formations had a fivefold rotational symmetry. Shechtman first observed these behaviors when researching reactions between aluminum and manganese.
Another researcher at NIST, Andrew Iams, expanded upon what Shechtman started when studying 3D-printed aluminum. In 2025, he confirmed the presence of quasicrystals under an electron microscope, revealing why the material had such superb strength. The study confirmed it is possible to manufacture this structure with 3D printers, making on-demand, high-strength metals a reliable option for even the most intensive industries, like aerospace and automotive.
How the rare crystal structure transforms industry
The research study drastically increases the utility of 3D-printed metals, encouraging competitors and thought leaders to invest in machinery. It could change economic conditions and lead to the faster adoption of automation technologies.
The shift will promote greater literacy in tech-forward additive manufacturing, including how to better balance elemental inputs for higher-quality metal output. Printers require adequate nitrogen levels to keep prints inert, prevent combustion and minimize oxidation. The knowledge is crucial for metals, which are vulnerable to these elemental influences.
The structure is also game-changing because it makes printing aluminum alloys easier, which is notoriously hard to do because of the high temperature requirements. Most 3D printers attempt it but often produce cracks and other defects because of how much the change in temperature alters the metal’s structure, rendering them useless and noncompliant.
Aluminum’s atomic structure is not conducive to these environments, but researchers discovered ways to make it suitable. Eventually, they found that zirconia compensates for aluminum’s weaknesses, making it viable for 3D prints.
Why 3D printing creates stronger metals
The atomic structure of more common crystal types produces characteristics in metals that encourage them to bend or break. When structures repeat, metals are more vulnerable to stressors. Introducing additives to form quasicrystals stabilizes atomic activity by adding nonrepeating fixtures, preventing it from altering the metal’s traits as it moves.
Industrial manufacturing becomes possible with a more malleable and consistent feedstock for the most popular metal-printing techniques. Powder bed fusion is the most dependable and widespread method. It uses electron beams and selective laser melting to form materials. It constructs metal by layering powder and melting it, with some technologies encouraging minimal waste by recycling excess for later prints.
Printers allow engineers to create more diverse shapes than conventional creation methods. The pieces are adhered more strongly, crafting more reliable parts for delicate installations like fuel nozzles and vehicle chassis.
Previously, these components were handfuls of smaller pieces assembled into a larger product with questionable stability. Producing a single, lightweight unit with improved cohesion is essential for making technologies safer to use and longer-lasting.
How to implement metal 3d printing in industry
The advantages of printing stronger aluminum alloys make upfront capital costs for infrastructure more justifiable, especially when it forges a more consistent and durable product. Sectors, such as military, aviation and automotive, can take these steps to start gaining the benefits of these rare crystal structures.
Select a printing process
Ensure the printing method supports the aluminum alloy powder that produces quasicrystals. While powder bed fusion is always an option, other avenues include binder jetting and direct energy deposition.
Execute comparative analysis
Designers and engineers want the improved strength characteristics of these 3D-printed metals. However, they must weigh existing designs against the new blueprints to ensure the models do not deviate from previously effective designs. This will prevent unintentional defects, like shrinkage.
Use digital twins
Even though they can be recycled, companies should digitally visualize prototypes before sending projects to print. These simulations are crucial for reviewing compliance and preventing unnecessary energy waste. Printing metals is a time-consuming endeavor, so this will also shorten lead times, leading to better fulfillment.
Maintain a culture of continuous improvement
Encourage staff to participate in continuing education, as 3D printing and additive manufacturing are constantly evolving. New materials may support quasicrystal formation, and workers will need to learn how to use these formulations, too.
They will also need to constantly adjust environmental metrics to support consistent output. Atmosphere, humidity and temperature control are important criteria impacting a 3D printer’s performance. While the product’s creation is automated, oversight is still required before, during and after processing.
Enhancing 3D-printed metal strength for competitive manufacturing
Additive manufacturing has made printing aluminum and other stronger metals possible by changing their atomic structure. Quasicrystals, which were previously considered a myth, are now replicable for large-scale industrial applications. Stakeholders must support investments in 3D printing technologies and continued research into these crystal structures. Eventually, it could unveil more ways to manipulate metals for improved longevity and environmental resistance.
About the author:
Emily Newton is a tech and industrial journalist and the Editor-in-Chief of Revolutionized magazine. Subscribe to the Revolutionized newsletter for more content from Emily.
Rare Crystal
3D-Printed Metal Parts
3D printing
National Institute of Standards and Technology
NIST
aluminum alloys
Quasicrystals
Dan Shechtman
Nobel Prize in Chemistry
Emily Newton
Andrew Iams
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