prototype 3D printing system capable of processing multiple metals at once. This new approach could dramatically reduce manufacturing time and material waste, opening opportunities across aerospace, automotive, and industrial applications.
Rotating Platform for Faster Production
Unlike conventional laser powder bed fusion machines, which apply and melt one layer at a time, the ETH system uses a rotating platform that enables powder deposition and laser fusion to occur simultaneously. This continuous process reduces production time for cylindrical components, such as rocket nozzles or turbine parts, by more than two-thirds.
Printing with Multiple Metals
The printer can process two metals in a single operation, a feature that is particularly useful for components exposed to extreme conditions. For example, rocket nozzles benefit from an inner copper lining for heat conduction and an outer nickel alloy shell for heat resistance. Conventional systems require multiple steps and large quantities of powder, much of which goes to waste. By depositing material only where it is needed, the new process minimises waste and improves efficiency.
Sustainable Material Use
The system addresses a key sustainability challenge in metal additive manufacturing: material circularity. Current 3D printing processes often struggle to recover mixed powders, leading to significant losses. ETH’s approach helps to avoid unnecessary waste, lowering costs and reducing environmental impact. For industries moving toward greener production, this innovation offers a pathway to more responsible resource use.
Potential Applications Beyond Aerospace
While the project was developed for the Swiss Academic Space Initiative (ARIS), which builds its own rockets, the method has broader potential. Applications may extend to gas turbines, aircraft components, and electric motors, where ring-shaped geometries and multi-material construction are common. The technology could also influence future developments in lightweight product design and sustainable manufacturing.
More information: Markus Bambach et al, Design and analyses of powder deposition, gas flow, and productivity for a rotary laser powder bed fusion system, CIRP Annals (2025).
DOI: 10.1016/j.cirp.2025.04.005.
