Additive Manufacturing

What Is Additive Manufacturing?

Additive manufacturing, often called 3D printing, is a process of building parts layer by layer directly from a digital model. It enables complex geometries, lightweight structures, and rapid prototyping with minimal material waste. Common methods include laser powder bed fusion (LPBF), stereolithography (SLA), and fused deposition modeling (FDM).

MetalTek uses additive manufacturing for low-volume production, rapid prototyping, and patternmaking, helping customers shorten development cycles and reduce lead times.

Unlike standalone additive providers, MetalTek combines additive manufacturing with metal casting expertise. This allows us to:

Recommend the optimal manufacturing process based on your needs
Support a seamless transition from prototype to production
Deliver a single trusted source for critical components

Laser Powder Bed Fusion MetalTek — Laser Powder Bed Fusion (LPBF) supports aerospace and space exploration, defense, energy, and industrial applications requiring complex, high-performance metal components.

Contact a MetalTek Key Account Manager to discuss how additive manufacturing can support low-volume production, as well as accelerate development and reduce lead times for metal cast components.

What Is Laser Powder Bed Fusion (LPBF) Additive Manufacturing?

Laser powder bed fusion (LPBF) is a precision metal additive manufacturing process that builds components layer by layer using a high-powered laser to fuse metal powder. The result is precise geometries, fine detail, and exceptional material performance. LPBF is also commonly known as DMLS (Direct Metal Laser Sintering) and SLM (Selective Laser Melting).

MetalTek's Wisconsin Investcast Division offers LPBF additive manufacturing for low-volume production of high-performance metal components using the superalloy MTEK 718 (Nickel 718). This capability supports manufacturers in aerospace and space exploration, defense, energy, and industrial markets that require complex, high-performance components for high-temperature, high-stress, and corrosive environments.

LPBF is ideal for production when traditional methods such as metal casting (including investment casting) or hog-out machining are not practical for low-volume applications, complex geometries, or accelerated production timelines.

How Laser Powder Bed Fusion Works

The LPBF process can be broken down into four primary stages. For a more detailed explanation of the LPBF process, read our blog: How Laser Powder Bed Fusion Works for Metal Additive Manufacturing.

What is Laser Powder Bed Fusion — In laser powder bed fusion, a laser melts fine metal powder, fusing it to the layer below and forming a dense metal structure.

1. Thin Layer of Metal Powder Is Applied. A recoater spreads a thin, uniform layer of metal powder across the build platform within an inert-gas chamber.

2. Laser Selectively Fuses the Powder. Using a digital CAD model, a high-powered laser scans the part’s cross-section and selectively melts the metal powder to form a solid metal layer.

3. The Process Repeats Layer by Layer. The build platform lowers, a new layer of powder is applied, and the laser repeats the process until the component is complete.

4. Post-Processing Prepares the Final Component. After printing, components typically undergo post-processing operations to meet final dimensional and performance requirements.

LPBF for Low-Volume Production

LPBF additive manufacturing is ideal for low-volume production when:

Production volumes are too low to justify metal casting tooling
Hog-out machining would result in excessive material waste or cost
Complex geometries are difficult or inefficient with traditional methods
Accelerated production timelines are required for critical components

Wisconsin Investcast has an LPBF part size envelope up to 12.4 in. diameter by 15.75 in. height (315 mm by 400 mm).

Benefits Of MTEK 718 (Nickel 718) For LPBF

MTEK 718 (Nickel 718) is a proven superalloy widely used in aerospace, defense, energy, and other demanding industrial environments. MTEK 718 is selected for applications requiring:

High strength at elevated temperatures
Excellent fatigue and creep resistance
Resistance to oxidation and corrosion

LPBF using MTEK 718 is ideal for components requiring high strength, complex geometry, and resistance to high heat, fatigue, and corrosion.

Using Additive Manufacturing With Metal Casting

Additive manufacturing can complement metal casting by shortening lead times, accelerating development, and increasing design flexibility. By combining these processes, manufacturers gain the design versatility of additive manufacturing alongside the proven durability and material performance of cast components. Understanding when to use additive manufacturing vs. casting is critical for optimizing both cost and performance. MetalTek uses additive technologies to accelerate early-stage development and to streamline metal casting production.

Using Additive Manufacturing With Metal Casting

Understanding when to use additive manufacturing vs. casting is critical for optimizing both cost and performance.

MetalTek uses additive manufacturing technologies to help streamline metal casting programs by:

Accelerating early-stage development
Streamlining the transition to production-ready cast components
Improving manufacturing flexibility for complex applications

What is SLA — Additive manufacturing technologies such as stereolithography (SLA) help to improve metal casting lead times by shortening development cycles and enabling faster pattern production.

Rapid Prototyping For Metal Casting

Additive manufacturing enables faster production of prototypes to support investment casting development. Processes such as laser powder bed fusion (LPBF) and stereolithography (SLA) are used to evaluate geometry, validate designs, and reduce development risk before committing to production.

These capabilities help shorten development cycles and accelerate the
transition to production-ready cast components.

Patternmaking for Metal Casting

Additive manufacturing is used to produce patterns for investment casting and sand casting, reducing reliance on traditional tooling. Technologies such as SLA and fused deposition modeling (FDM) enable faster pattern production and greater flexibility for low-volume or complex components.

This approach helps shorten lead times and improve efficiency in early-stage and low-volume casting programs.