Desktop Metal qualifies Continuum Powders' recycled superalloy for additive manufacturing.

In a significant step toward advancing sustainable additive manufacturing (AM), Desktop Metal Inc. has qualified Continuum Powders Corp.'s 100% recycled Mar-M247 superalloy for use in its binder jet 3D printers, marking the first time a fully recycled alloy has been approved for the company's metal printing platforms.

The adoption of recycled metals in 3D printing has faced significant technical challenges, primarily due to the difficulty in maintaining material consistency throughout the recycling process.

Recycled metals often contain impurities or exhibit altered mechanical properties, making them less reliable for critical applications such as aerospace or automotive components, ensuring the same level of purity and reliability as virgin metals is essential to maintaining the strength, durability, and thermal resistance of 3D-printed parts.

Beyond issues of purity and mechanical properties, the morphology (shape and structure) and size of recycled metal particles present further challenges.

Irregularities in particle shape or size can hinder material flow during the printing process, potentially causing defects like porosity (tiny air pockets) or weak spots. This is particularly problematic in binder jetting, where achieving a uniform powder layer is critical to ensuring the structural integrity of the final product.

One of the key steps in producing metal powders for 3D printing is the atomization process, which transforms molten metals into fine powder particles by spraying the material through a nozzle while being quenched by high-pressure gas or liquid to break it into tiny droplets that quickly cool and solidify into uniform particulates.

These metal powders must meet stringent quality standards for size, shape, and purity to ensure they are suitable for additive manufacturing. However, even during the atomization process, irregularities in particle shape or size often occur, affecting the material's flowability and, consequently, the quality of the final printed part.

To address these challenges, Continuum Powders has developed a proprietary re-atomization technology that enables 100% recycled metals, like its Mar-M247 superalloy, to meet the stringent requirements for high-performance 3D printing.

Recognizing the potential of this breakthrough, Desktop Metal has qualified Mar-M247 under its rigorous material qualification system.

This system includes three tiers: DM-qualified, where materials meet fully characterized mechanical properties and industry standards; customer-qualified, where clients validate the material for their specific applications; and research and development materials, which are still being tested.

The qualification of Mar-M247 as research and development demonstrates its readiness for further refinement and integration into Desktop Metal's binder jet printing technology.

"The fact that we're seeing reclaimed metal powders validated by Desktop Metal, along with other leading AM OEMs (original equipment manufacturers), signals that these materials are now a proven resource for manufacturers," said Continuum Powders CEO Rob Higby. "Use of recycled powders can shorten supply chains, reduce costs and support corporate goals for carbon footprint reduction."

Desktop Metal Inc.

Desktop Metal's X-Series 3D printers from left to right: InnoventX, ideal for research and low-volume production; X25Pro, a mid-sized printer for volume production; and X160Pro, the world's largest metal binder jet system.

By utilizing its X25Pro platform– a binder jet 3D printer tailored for large-scale metal component production– along with its Triple ACT (Advanced Compaction Technology), Desktop Metal ensures the precise distribution of powder layers, enhancing the mechanical properties of printed products.

This precise process is key to qualifying materials like Continuum Powders' Mar-M247 superalloy, demonstrating its ability to meet the high standards required for sustainable, high-performance 3D printing applications.

Desktop Metal's choice to qualify Continuum Powders' Mar-M247 superalloy also reflects its focus on integrating sustainable materials into its 3D printing portfolio and supports the company's goal to reduce environmental impact without compromising the performance of its products.

By qualifying the 100% recycled alloy, Desktop Metal aims to enhance the adoption of eco-friendly materials in industries like aerospace and automotive, with plans to expand the development and use of recycled powders for future applications.

"We see a bright future for high-quality, sustainable powder options for our additive manufacturing technologies," said Desktop Metal CEO Ric Fulop. "Having a qualified 100% reclaimed metal powder from Continuum Powders is just a first step in what we hope is a long line of recycled, eco-conscious materials that offer a significant return on investment."