Source: Horizon Grand View Research

Real-world impact

During the COVID-19 pandemic, when supply chains were disrupted globally, Amace Solutions demonstrated the power of 3D metal printing. In just 20 hours, they designed, printed, and delivered critical ventilator parts. Dr Vishwas R Puttige, CEO, Amace Solutions, shares his experience, “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.”                              

This rapid response isn’t limited to medical emergencies. Amace also played a pivotal role in India’s Chandrayaan-3 mission. The Pragyan rover, which marked India’s lunar success, featured wheels etched with the ISRO logo and the national emblem, crafted with unmatched precision using 3D printing.

The automotive industry, too, has embraced this innovation. Companies like Bajaj Auto and Hero MotoCorp use 3D metal printing for rapid prototyping and design validation. Dr Puttige highlighted a standout project, “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.”

Addressing challenges

Despite its advantages, 3D metal printing faces challenges. Yathiraj Kasal, General Manager and Business Head, Wipro 3D, elaborated on these hurdles:

?       Complex geometries: The enhanced design possibilities of 3D printing often result in geometrically complex features. Machining supports for these intricate designs and ensuring no unfused powder remains trapped in internal channels is a significant challenge.

?       Material limitations: The range of materials suitable for 3D printing is still limited compared to traditional manufacturing. Designers must account for material availability during the design phase to avoid delays or surprises during production.

?       Dimensional accuracy: Achieving the necessary dimensions and tolerances for functional requirements remains a critical focus area.

Recent trends

The field of 3D metal printing is constantly evolving. Kasal highlights several recent trends shaping the industry, “Multi-material printing is enabling the integration of diverse materials in a single component, enhancing functionality and performance for industries like aerospace and healthcare. Multi-laser systems are reducing print times, making large-scale production more practical and efficient.”

Engineers are also adopting lightweight designs, inspired by nature, to minimise material use while maintaining strength, benefiting sectors like automotive and aerospace. Additionally, component consolidation allows multiple parts to be combined into a single unit, simplifying assembly and cutting costs.

These trends showcase the growing impact of 3D metal printing on innovation and manufacturing efficiency across industries.

The future

Additive manufacturing is revolutionising the metalworking industry by offering unprecedented design freedom and efficiency. Amit Raina, Country Manager-India, Dormer Pramet, comments, “Traditional manufacturing methods often result in significant material wastage, especially during machining, where excess material is removed to achieve the final shape. In contrast, 3D printing minimises waste by constructing parts layer by layer, using only the exact amount of material required. This precision not only cuts down on waste but also reduces costs and improves sustainability.”

Additionally, 3D printing enhances production speed by enabling rapid prototyping and quick design iterations. This acceleration of the product development cycle allows manufacturers to bring products to market much faster than with conventional methods, making it an invaluable tool for industries that prioritise speed and innovation.

Customisation and technological advancements

The ability to produce customised parts on demand is another transformative aspect of 3D metal printing. This capability is especially valuable in industries such as healthcare and aerospace, where specialised, tailored components are often needed. 3D printing makes it easier and more cost-effective to meet these niche demands, opening the door for highly personalised manufacturing solutions.

Looking to the future, breakthrough technologies in 3D metal printing are expected to revolutionise the industry even further. Industry leaders, like Fronius, are excited about two key advancements that promise to reshape manufacturing processes.

One is the closed-loop feedback system, which allows for real-time process control and material characterisation. This system will improve both precision and quality assurance, ensuring manufacturers can achieve greater reliability and efficiency in their production.

Another promising technology is Cold Metal Transfer (CMT), exemplified by the Fronius CMT Additive Pro process. This system delivers high deposition rates and precise molten pool control, making it ideal for producing high-quality, complex parts, especially when working with difficult-to-weld alloys. The CMT process is particularly suited for high-volume production and applications that demand tight tolerances, further expanding the capabilities of 3D metal printing.

Expanding applications

As the technology matures, its applications continue to grow. Sectors such as healthcare are leveraging 3D printing for custom implants and prosthetics. Aerospace manufacturers are producing lightweight, high-strength components, while the defence industry is exploring its potential for rapid prototyping and low-volume production.

India’s 3D printing ecosystem is steadily expanding, with companies like Amace Solutions, Wipro 3D, and others leading the charge. The country’s focus on Aatmanirbhar Bharat and Make in India are further driving the adoption of advanced manufacturing technologies. Investments in research, infrastructure, and skill development will be crucial in realising the full potential of 3D metal printing.

Conclusion

3D metal printing is India’s ticket to the future of manufacturing. Its ability to defy traditional constraints, reduce time-to-market, and enable customisation makes it a game-changer. As industries continue to innovate and adopt new technologies, India stands on the brink of becoming a global powerhouse in additive manufacturing. The journey has only just begun, and the possibilities are limitless.