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Japanese researchers have introduced an innovative 3D printing technique capable of manufacturing automotive parts with greater efficiency and precision.
Researchers from Tohoku University, in Japan, achieved a historic technological milestone by developing a highly durable steel and aluminum alloy through 3D printing. Japanese innovation has the potential to transform the manufacturing of automotive parts by combining lightness and strength, solving historical challenges in the use of multi-materials.
Advances in 3D metal printing
The metal 3D printing technique allows objects to be built layer by layer, joining materials precisely using heat.
This approach offers advantages such as reducing waste and creating customizable shapes, making it essential in modern manufacturing.
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However, creating multi-material structures — such as integrating steel and aluminum — requires advanced solutions to overcome the formation of brittle composites, a common problem when different metals are combined.
"Multi-materials are a central theme in additive manufacturing due to the flexibility of the process“, explained Professor Kenta Yamanaka of the Materials Research Institute at Tohoku University. “However, brittle intermetallic compounds can arise, making the material lighter but also more brittle."
How to overcome the technical challenge
The team used a technique called Laser powder bed fusion (L-PBF), which employs lasers to selectively melt metal powders.
This method was essential to suppress the formation of brittle compounds such as Al5Fe2 and Al13Fe4 at the interfaces between steel and aluminum.
They found that increasing the laser scanning speed favors non-equilibrium solidification, minimizing the structural weaknesses of the material. The result was a robust alloy with strong bonding interfaces, ready for industrial applications.
"It's not just about putting two metals together and expecting them to stick.”, said Seungkyun Yim, assistant professor at Tohoku University. “It was essential to understand the alloying mechanism in situ to ensure durability."
First practical application
Based on this research, the group created the world's first full-scale multi-material automotive component.
The prototype, a suspension tower with customized geometry, combines lightness and resistance in an unprecedented way.
The part, essential for vehicle performance, marks a significant advance in the automotive sector, where reducing weight without compromising safety is a priority.
Implications for the automotive industry
Tohoku University's innovation opens up new possibilities for producing lighter, more economical and sustainable vehicles.
Reducing the weight of components can improve the energy efficiency of automobiles, helping to meet global demands for environmentally responsible solutions.
The researchers are already planning to apply the method to other metal combinations, expanding the use of the technique to sectors beyond the automotive sector. This includes the creation of aerospace parts and even medical equipment, where lightness and durability are equally crucial.
The results of the study were published in the journal Additive Manufacturing on November 19, 2024, highlighting the potential impact of this technology on advanced manufacturing.
With this advancement, 3D metal printing takes an important step towards a future where combining materials will become increasingly efficient, safe and accessible. The bet is that innovations like this will accelerate the development of customized, high-performance products.
