Researchers at University College London, and the University of Greenwich have developed a technique to reduce flaws in 3D printed components. This method has the potential to enhance the manufacturing of safety-critical parts for industries like aerospace and high performance motorsports, including Formula 1.Supported by the UK EPSRC and the Royal Academy of Engineering, the research uses X-ray imaging to observe defects in 3D printed metal alloy parts. If adopted, this technique could also improve the strength and durability of parts such as artificial hip joints and aircraft components.3D printed metal alloy components. Photo via: UCL.Understanding the Forces Behind Metal Alloy 3D PrintingThe Study: Investigating Laser-Based 3D Printing and Magnetic FieldsWhen we apply a magnetic field to this process, thermoelectric forces cause a fluid flow that helps to stabilize the hole so that it resembles an I shape, with no tail to break off when it ripples, said Dr. Xianqiang Fan, Author of the study, UCL Mechanical Engineering.The researchers used an X-ray microbeam, during printing, to locally measure liquid crystal alignment and direction inside the printer nozzle. Image via Harvard SEAS.Implications and Future ApplicationsWhether it is fabricating artificial hips or battery packs for electric vehicles, improvements in additive manufacturing will make it quicker and cheaper to produce 3D printed components that are also of higher quality,said Professor Andrew Kao, Senior Author of the study from the University of Greenwich.However, the researchers acknowledge that incorporating magnetic fields into production lines will face technical challenges. These challenges may take several years to overcome, but the potential to produce higher-quality, more durable components in industries such as aerospace and biomedical manufacturing is significant.Efforts to Enhance Durability in MaterialsNASAs newly developed GRX-810, an oxide dispersion strengthened (ODS) alloy, represents a significant advancement in aerospace materials. This metal, designed for high-performance aerospace systems, combines exceptional strength and durability, capable of withstanding temperatures exceeding 1090C (2000F) while offering greater malleability than traditional aerospace alloys.In 2024, researchers at the Massachusetts Institute of Technology (MIT) introduced a new heat treatment method to enhance the strength of 3D printed metals. This new technique modifies the microscopic structures of 3D printed components, improving their durability and resistance to thermal shock, further advancing the field of additive manufacturing in high-performance applications.What 3D printing trends should you watch out for in 2025?How is the future of 3D printing shaping up?To stay up to date with the latest 3D printing news, dont forget to subscribe to the 3D Printing Industry newsletter or follow us onLinkedin.While youre here, why not subscribe to our YouTube channel? Featuring discussion, debriefs, video shorts, and webinar replays.Featured image shows 3D printed metal alloy components. Photo via: UCL.