We are one of the frontrunners in this space in India. Our machines have been adopted by a variety of industries and organisations, including; ISRO, DRDO, private sector industries like automotive and mold-making companies, as well as educational institutions, Dr Vishwas R Puttige, CEO, Amace Solutions Pvt Ltd in dialogue with Sanskriti Ramachandran explores the intricacies of 3D metal printing and its challenges.

Amace Solutions Private Limited, also known as Amace, is part of the Ace Micromatic Group, which is a subsidiary of IS Designers Limited. The group has been a leader in metal cutting for nearly 50 years, specialising in CNC turning machines, CNC milling machines, and other metal-cutting technologies. We have catered to both domestic and international markets, with over 100,000 machines installed worldwide. This makes us the largest provider of CNC technology in India. Amace Solutions started as an R&D project approximately eight years ago and was spun off as an independent company in early 2018.

We focus on two primary areas. First, we manufacture and sell metal 3D printers, and we are one of the frontrunners in this space in India. Our machines have been adopted by a variety of industries and organisations, including ISRO, DRDO, private sector industries like automotive and mold-making companies, as well as educational institutions. Second, we offer 3D printing services for customers who wish to explore the benefits of 3D metal printing or additive manufacturing before investing in the technology themselves. These services include printing parts, consultancy, training, and helping customers build awareness about 3D printing. We assist in digitising their inventory and converting conventional components into 3D-printable designs.

The key sectors we cater to include space technology, medical technology, defence, aerospace, automotive, general engineering, and education. These are evolving industries where 3D printing is rapidly gaining traction, and we are committed to serving their needs effectively.

We work with a wide range of materials to meet the needs of various applications. Our expertise includes stainless steel, aluminum alloys, titanium alloys, Inconel (a nickel-based, high-temperature-resistant alloy), and maraging steel (a high-strength steel). We also handle niche materials like cobalt-chrome and copper-based alloys. In addition to the established materials, we are actively developing new alloys and materials tailored to specific customer requirements.

There are several challenges in 3D metal printing. The first is identifying which components are suitable for 3D printing. Many customers are not aware of which parts are worth converting, making screening a critical step. Another challenge is the limited availability of materials. While conventional manufacturing processes use over 5,000 types of metals, 3D metal printing currently works with only about 25–30 materials, though this number is increasing steadily. Post-processing is another significant challenge. After printing, components often require secondary machining or finishing processes to achieve high accuracy and surface quality, particularly for mating surfaces or critical tolerances.

Incorporating new materials is a critical part of our R&D efforts. We prioritise material development based on demand. When there is growing interest in a specific material for an application, we take up its development and validation. Once finalised, we offer it to our customers, ensuring it meets their specific needs and expands the potential of 3D printing applications.

We have numerous success stories. One notable example is from the COVID-19 pandemic when a customer urgently required ventilator parts. Within 20 hours, we managed to generate a quotation, receive a purchase order, print the required parts, and ship them. This demonstrated the speed and efficiency of 3D printing. Another proud moment was our contribution to ISRO’s Chandrayaan-3 mission. The Pragyan rover, which left India’s footprint on the moon, had wheels bearing an ISRO logo and the Indian national emblem. Amace printed the national emblem, a significant milestone for us.

In the automotive sector, we have helped companies like Bajaj Auto and Hero MotoCorp rapidly validate their designs using metal 3D printing. For instance, we collaborated with an electric motorcycle startup to produce 3D-printed components for three motorcycles in just 15 days. The assembly process took another 15 days, and within 30 days, the entire project was completed. One of these motorcycles set a Guinness World Record by covering over 14,000 kilometers across India without any issues. These examples highlight how 3D printing can accelerate design validation and reduce time-to-market for various industries.

The 3D metal printing industry is witnessing several exciting trends. Machines are becoming larger and more productive while simultaneously becoming more affordable. New materials are being developed at a rapid pace, further enhancing adoption. The technology is also making significant inroads into niche markets such as electronics, semiconductor manufacturing, and space technology. For example, rocket engines with complex geometries are now being successfully 3D printed. These advancements are bringing 3D metal printing closer to becoming a mainstream manufacturing process.

Our primary goal is to continuously enhance the productivity and usability of our machines. We are working on incorporating smart features and sensors to improve the user interface and make the machines more customer-friendly. Additionally, we are focused on expanding into the education sector domestically, where 3D metal printing is gaining significant traction. Internationally, we see increasing opportunities in North America and Europe as more customers recognise India’s potential as a reliable equipment supplier. We are optimistic about the growing demand for our machines in these regions.

The next big breakthrough will likely involve integrating advanced software features, AI-driven manufacturing processes, and digital manufacturing techniques. Machines will become more productive and affordable, bridging the gap between 3D printing and conventional methods like investment casting. This will help dispel the perception of 3D metal printing as an expensive, niche technology. As manufacturing trends shift towards smaller production volumes with higher variety, the flexibility and efficiency of 3D metal printing will make it an indispensable tool. With these advancements, the adoption of Agile manufacturing and digital processes will revolutionise the industry both in India and globally.