• Home
  • Latest
  • Fortune 500
  • Finance
  • Tech
  • Leadership
  • Lifestyle
  • Rankings
  • Multimedia

Trendingnow

1

He worked 100-hour weeks to save a nearly bankrupt boat company. At 83, he’s just turned down $400 million for it—and gave it all to charity instead

2

Costco's $14 million email settlement: Who qualifies for an up-to $500 payment and how to claim before the Aug. 24 deadline

3

Mamdani’s pied-à-terre tax was designed to hit the wealthy, but it’s sending most New Yorkers to their estate lawyers

1

He worked 100-hour weeks to save a nearly bankrupt boat company. At 83, he’s just turned down $400 million for it—and gave it all to charity instead

2

Costco's $14 million email settlement: Who qualifies for an up-to $500 payment and how to claim before the Aug. 24 deadline

3

Mamdani’s pied-à-terre tax was designed to hit the wealthy, but it’s sending most New Yorkers to their estate lawyers
Tech3d printing

Here’s Why 3D Printing Needs More Metal

By
Andrew Zaleski
Andrew Zaleski
Down Arrow Button Icon
By
Andrew Zaleski
Andrew Zaleski
Down Arrow Button Icon
November 11, 2015, 12:19 PM ET
Photo courtesy of Alcoa
Add Fortune on Google for similar content.

Alcoa, a colossus of the aluminum and metals industry, is currently building a new additive manufacturing center with a $60 million price tag in Pittsburgh. Its purpose: To serve as the main production site as Alcoa begins developing a line of powdered metals made specifically for 3D-printing applications. What Alcoa’s new center represents, however, is a broader shift taking shape in the additive manufacturing industry.

More companies in a variety of sectors are interested in using 3D-printed metals for end-use parts. But when it comes to 3D printing in metals, there are currently two problems to surmount. One is the overall cost of not only the additive processes by which metal is printed, but also of the 3D printing machines and the support staff needed to run them. The other is the cost of the metal materials themselves and the lack of metal materials made specifically for 3D printing. Alcoa (AA) is hoping to find solutions for both problems when its new additive manufacturing center opens, as Rod Heiple, the company’s director of R&D for engineered products and solutions, said during a call with Fortune.

“There are just a few materials available today that are usable within 3D printing of metals,” Heiple said. “A material developed as a feedstock for one additive process may not be, and in fact is unlikely to be, the optimal material for the next additive manufacturing process.”

Today companies that produce metal parts via additive manufacturing processes are using powdered titanium, nickel, aluminum, and steel. Direct metal laser sintering is a common way for these powdered metals to come together to make solid objects. It’s how General Electric produced the fuel nozzles for its bestselling aircraft engine and Solid Concepts created a working firearm.

MORE: Why 3D Printing Is The Future of Manufacturing

But optimizing powders for 3D printing is the challenge. Solving that challenge would not only mean a greater number of powdered metals for use in 3D printing, but also cheaper powdered metals. This is the sort of task for which Alcoa is well-suited. The company has nearly 100 years of experience in the atomizing process (the means by which a molten metal is converted into a powdered metal).

“That’s the focus we have, the optimization. We’re looking at the chemistry, the alloy elements,” said Heiple. “In the case of powdered feedstock, we’re focused on developing powders that are shapes and sizes tailored to 3D printing. Our primary focus is on titanium, aluminum, and nickel-based alloys for 3D printing.”

While the technology is fascinating in its own right, the business imperative is driving the research in cheaper powdered metals made specifically for 3D printing. Companies’ primary reasons for investing in additive manufacturing capabilities are the cost reductions that accompany collapsing the manufacturing supply chain. When GE, for example, chooses to invest $3.5 billion to purchase the 3D-printing machines that can produce metal parts and train the staff needed to run them, it’s not doing so because the technology is cool—it’s doing so because that’s where the additive manufacturing industry is headed.

A recent report from Stratasys Direct Manufacturing, the service arm of 3D-printing company Stratasys (SSYS), bears this out: More than 80% of 700 survey respondents from the manufacturing industry said further development of strong yet lightweight metals for additive manufacturing is what they want the most. In three years’ time, Stratasys Direct Manufacturing predicts use of metals in 3D printing to double.

Stratasys and 3D Systems (DDD), two titans of the 3D-printing sector, are keen to make inroads in metals printing as well. The increasing focus on what metals printing will do for the overall additive manufacturing industry—currently valued worldwide at $4.1 billion, according to the latest report from consulting firm Wohlers Associates—is the reason, for instance, Stratasys acquired Solid Concepts in 2014 and 3D Systems just established a partnership with the U.S. Army to develop 3D-printing materials for the automotive, medical, and aerospace industries.

The market for prototyping via 3D printing remains weak, but metals printing continues to grow at an impressive clip. More than just a new way for companies to make end-use parts, direct metal printing represents an area of revenue growth for an industry that has struggled to live up to the hype.

“The opportunity here is that these metals materials for additive manufacturing are low in number,” said Heiple, who couldn’t comment about the timeframe for when Alcoa’s new additive manufacturing center opens (although a company press release from September estimates sometime in the first quarter of 2016). “And the reason there’s an interest in metals is it all comes down to cost reduction, in end product and end solutions.”

In other words, there’s a growing movement of companies interested in crossing the chasm between 3D printing as a neat prototyping tool and 3D printing as a production tool on par with traditional manufacturing processes. To do that, they’ll need metals.

Sign up for Data Sheet, Fortune’s daily newsletter about the business of technology.

For more Fortune coverage of 3D printing, watch this video:

About the Author
By Andrew Zaleski
See full bioRight Arrow Button Icon
Add Fortune on Google for similar content.

Latest in Tech

Finance
Lorem ipsum dolor sit amet, consectetur adipiscing elit, sed do eiusmod tempor incididunt ut labore et dolore magna aliqua. Ut enim ad minim veniam
By Fortune Editors
October 20, 2025
Finance
Lorem ipsum dolor sit amet, consectetur adipiscing elit, sed do eiusmod tempor incididunt ut labore et dolore magna aliqua. Ut enim ad minim veniam
By Fortune Editors
October 20, 2025
Finance
Lorem ipsum dolor sit amet, consectetur adipiscing elit, sed do eiusmod tempor incididunt ut labore et dolore magna aliqua. Ut enim ad minim veniam
By Fortune Editors
October 20, 2025
Finance
Lorem ipsum dolor sit amet, consectetur adipiscing elit, sed do eiusmod tempor incididunt ut labore et dolore magna aliqua. Ut enim ad minim veniam
By Fortune Editors
October 20, 2025
Finance
Lorem ipsum dolor sit amet, consectetur adipiscing elit, sed do eiusmod tempor incididunt ut labore et dolore magna aliqua. Ut enim ad minim veniam
By Fortune Editors
October 20, 2025
Finance
Lorem ipsum dolor sit amet, consectetur adipiscing elit, sed do eiusmod tempor incididunt ut labore et dolore magna aliqua. Ut enim ad minim veniam
By Fortune Editors
October 20, 2025

Most Popular

Finance
Lorem ipsum dolor sit amet, consectetur adipiscing elit, sed do eiusmod tempor incididunt ut labore et dolore magna aliqua. Ut enim ad minim veniam
By Fortune Editors
October 20, 2025
Finance
Lorem ipsum dolor sit amet, consectetur adipiscing elit, sed do eiusmod tempor incididunt ut labore et dolore magna aliqua. Ut enim ad minim veniam
By Fortune Editors
October 20, 2025
Finance
Lorem ipsum dolor sit amet, consectetur adipiscing elit, sed do eiusmod tempor incididunt ut labore et dolore magna aliqua. Ut enim ad minim veniam
By Fortune Editors
October 20, 2025
Finance
Lorem ipsum dolor sit amet, consectetur adipiscing elit, sed do eiusmod tempor incididunt ut labore et dolore magna aliqua. Ut enim ad minim veniam
By Fortune Editors
October 20, 2025
Finance
Lorem ipsum dolor sit amet, consectetur adipiscing elit, sed do eiusmod tempor incididunt ut labore et dolore magna aliqua. Ut enim ad minim veniam
By Fortune Editors
October 20, 2025
Finance
Lorem ipsum dolor sit amet, consectetur adipiscing elit, sed do eiusmod tempor incididunt ut labore et dolore magna aliqua. Ut enim ad minim veniam
By Fortune Editors
October 20, 2025
Fortune Secondary Logo
Rankings
  • 100 Best Companies
  • Fortune 500
  • Global 500
  • Fortune 500 Europe
  • Most Powerful Women
  • World's Most Admired Companies
  • See All Rankings
  • Lists Calendar
Sections
  • Finance
  • Fortune Crypto
  • Features
  • Leadership
  • Health
  • Commentary
  • Success
  • Retail
  • Mpw
  • Tech
  • Lifestyle
  • CEO Initiative
  • Asia
  • Politics
  • Conferences
  • Europe
  • Newsletters
  • Personal Finance
  • Environment
  • Magazine
  • Education
Customer Support
  • Frequently Asked Questions
  • Customer Service Portal
  • Privacy Policy
  • Terms Of Use
  • Single Issues For Purchase
  • International Print
Commercial Services
  • Advertising
  • Fortune Brand Studio
  • Fortune Analytics
  • Fortune Conferences
  • Business Development
  • Group Subscriptions
About Us
  • About Us
  • Press Center
  • Work At Fortune
  • Terms And Conditions
  • Site Map
  • About Us
  • Press Center
  • Work At Fortune
  • Terms And Conditions
  • Site Map
  • Facebook icon
  • Twitter icon
  • LinkedIn icon
  • Instagram icon
  • TikTok icon
  • YouTube icon

Latest in Tech

Should AI be formally recognized as a national and global security threat? In London, politicians increasingly think so 
EuropeLetter from London
Should AI be formally recognized as a national and global security threat? In London, politicians increasingly think so 
By Kamal AhmedJuly 30, 2026
52 minutes ago
musk
LawElon Musk
xAI sues Minnesota over law banning AI ‘nudification’ tech
By Marc Levy, Barbara Ortutay and The Associated PressJuly 30, 2026
2 hours ago
z
Big Techearnings
Meta earnings reveal cash flow drops 91% — while Zuckerberg writes op-eds about superintelligence
By Barbara Ortutay and The Associated PressJuly 30, 2026
2 hours ago
ss
AsiaMarkets
Samsung posts record $62 billion profit — and investors sell off anyway
By Nick Lichtenberg, Kim Tong-Hyung and The Associated PressJuly 30, 2026
2 hours ago
byd
CommentaryChina
McKinsey auto leader: China’s auto industry is faster, cheaper and better. Here’s how the West can close the gap 
By Philipp KampshoffJuly 30, 2026
5 hours ago
Jonathan Winer wears a white button down and blue sweater and smiles.
AITerm Sheet
Forget robots on assembly lines. Foundational Industries wants AI to run the entire factory
By Lily Mae LazarusJuly 30, 2026
6 hours ago

Most Popular

He worked 100-hour weeks to save a nearly bankrupt boat company. At 83, he’s just turned down $400 million for it—and gave it all to charity instead
Success
He worked 100-hour weeks to save a nearly bankrupt boat company. At 83, he’s just turned down $400 million for it—and gave it all to charity instead
By Preston ForeJuly 29, 2026
23 hours ago
Costco's $14 million email settlement: Who qualifies for an up-to $500 payment and how to claim before the Aug. 24 deadline
Retail
Costco's $14 million email settlement: Who qualifies for an up-to $500 payment and how to claim before the Aug. 24 deadline
By Sydney LakeJuly 29, 2026
1 day ago
Mamdani’s pied-à-terre tax was designed to hit the wealthy, but it’s sending most New Yorkers to their estate lawyers
Real Estate
Mamdani’s pied-à-terre tax was designed to hit the wealthy, but it’s sending most New Yorkers to their estate lawyers
By Catherina GioinoJuly 30, 2026
8 hours ago
Current price of oil as of July 29, 2026
Personal Finance
Current price of oil as of July 29, 2026
By Joseph HostetlerJuly 29, 2026
1 day ago
Millionaires are leaving the U.K. in droves thanks to tax hikes—but the CEO of $1 billion tax platform says it’s their ‘social responsibility’ to stay
Success
Millionaires are leaving the U.K. in droves thanks to tax hikes—but the CEO of $1 billion tax platform says it’s their ‘social responsibility’ to stay
By Orianna Rosa RoyleJuly 29, 2026
1 day ago
Jamie Dimon says his stockbroker father taught him to invest with a 'brutally hard' childhood game
C-Suite
Jamie Dimon says his stockbroker father taught him to invest with a 'brutally hard' childhood game
By Sarah GlodekJuly 29, 2026
1 day ago

© 2026 Fortune Media IP Limited. All Rights Reserved. Use of this site constitutes acceptance of our Terms of Use and Privacy Policy | CA Notice at Collection and Privacy Notice | Do Not Sell/Share My Personal Information
FORTUNE is a trademark of Fortune Media IP Limited, registered in the U.S. and other countries. FORTUNE may receive compensation for some links to products and services on this website. Offers may be subject to change without notice.