In order to overcome existing constraints in the in-service behavior of currently available additive manufacturing (AM) materials, an advanced production method for high-performance technology metals was developed based on a modified vat polymerization-based (VP) printing for metal powders. The new, innovative lithography-based metal manufacturing (LMM) process is able to photo-harden a photopolymeric binder that is highly filled with metal powder.

After debinding and sintering, the fully dense metal AM parts will provide various advantages such as superior properties with respect to cracks or internal stress when compared to laser-based powder bed fusion (L-PBF) AM parts. LMM is suitable to build very detailed, complex structures with a minimum of after treatments and without need for support structures. The LMM parts exhibit superior surface quality, are less demanding with respect to powder particle size/morphology and allow effective re-use of the feedstock materials.

The LMM process will be explained in detail. Its suitability for the production of jewelry and watch cases will be demonstrated for stainless steel-type materials and titanium alloys on various samples. Finally, an outlook for precious metal powders will be given.

Author: Dr. Carlo Burkhardt