Ultrasonic additive manufacturing (UAM) combines a unique room-temperature metal deposition process with the ease of traditional CNC milling. A patented ultrasonic print head is integrated into three-axis mills to create a hybrid additive-subtractive process.

Ford Performance collaborated with a team of European research engineers to design and manufacture an intricate aluminum intake manifold that supplies air from the turbochargers to the engine’s cylinders. The AM process to produce the almost 6-kg part was reported to have taken five days.

With 3D printing, improving strength is a big part of making the technology practical. A researcher at the University of Texas Arlington has done some work with thermal annealing and annealing with unidirectional (z-direction) pressure.

Yngwie Malmsteen is not exactly a household name in the U.S. Apparently, his ability and proclivity to smash guitars is legend. As a result, he was given a 3D-printed (AM) titanium guitar to try his best.

Creating 3D-printed parts that can react with their environment makes them 4D. Researchers in the U.K. have developed a multi-metal electrochemical 3D printer. Electrochemical additive manufacture (ECAM) is a relatively new metal AM technique, which eliminated the need for thermal processes.

Space doesn’t allow us to discuss the parts in detail, but Bugatti is using AM for a number of functional parts. These include: titanium brake caliber, active spoiler bracket made of titanium, motor bracket (AlSi10Mg) with integral cooling, front axle differential housing and cylinder-head cam covers.

Aerojet Rocketdyne Holdings Inc. recently acquired 3D Materials Technologies (3DMT), which is a provider of AM services to the aerospace, defense, medical and industrial markets. The plan is to develop and produce metal-alloy AM parts for aerospace propulsion and power systems

In the past few years, titanium AM spinal implants have gained in popularity. In that timeframe, more than 2,000 have been implanted into patients. It is expected that the AM components will replace the machined components in time.

China’s car market, going through its first contraction in more than 20 years, is damaging the demand for steel. According to a Reuters report, orders for hot-rolled coil (HRC), steel that is processed into metal sheets used for car bodies, are slowing down.

Several 2019 model-year vehicles are utilizing an advanced high-strength steel (AHSS) structure. In fact, more than 65 AHSS-intensive vehicles were unveiled across the country this year. AHSS was represented in every vehicle segment and size, including SUV and truck markets. For example, 98% of the steel used in the frame of the 2019 Ram 1500 is AHSS, and the 2019 Volkswagen Jetta is composed of 35% ultrahigh-strength hot-formed steel, 12% ultrahigh-strength steel and 39% extra-high-strength steel.