Metal Additive Manufacturing Moves Into Industrial Production

Metal additive manufacturing is expanding rapidly and reshaping the industrial landscape. In 2023, the global industrial 3D printing market reached $20 billion and is expected to grow at an annual rate of 15.8% between 2024 and 2032, according to gminsights.com. The energy, aerospace and defence sectors are among its fastest adopters. A review of several ongoing projects.

“Additive manufacturing has become a key lever for strengthening the sovereignty and competitiveness of France’s strategic industries. Framatome has made it a central pillar of its operations to secure supply chains and foster innovation in nuclear component design,” said Jean-Bernard Ville, Senior Executive Vice President, Projects and Component Manufacturing Business Unit at Framatome, during the groundbreaking ceremony for a new additive manufacturing facility at its Romans-sur-Isère site. This €25 million installation — unique in Europe — will produce mechanical components using metal 3D printing for the nuclear and defence sectors, deploying wire-arc additive manufacturing and laser powder-bed fusion processes. Components ranging from a few kilograms to several dozen tonnes will be produced. These technologies significantly reduce environmental impact through more efficient use of materials.

A hub for the nuclear sector

In the nuclear field, the French Alternative Energies and Atomic Energy Commission (CEA) and Nikon SLM Solutions have launched Mantra, a joint innovation hub dedicated to additive manufacturing of large-scale components for the nuclear industry. “With the Mantra Hub, our goal is to make additive manufacturing a reliable and competitive solution for the nuclear sector,” explains Stéphanie Riché, Head of the Materials Circular Economy Programme at CEA. “Our collaboration with Nikon SLM Solutions gives us access to cutting-edge technology in Europe and enables co-development aligned with the sector’s stringent standards. This partnership will benefit industrial stakeholders across Europe and beyond.”

Aerospace: manufacturing structural components

Research into additive manufacturing is also advancing rapidly in aerospace. One objective is to produce aircraft structural parts using 3D printing instead of machining, reducing the use of costly metals such as titanium and nickel. To support this development, the aerospace engineering school ISAE-Supaero and the materials research institute ICA (Institut Clément Ader) in Toulouse have installed a wire-arc additive manufacturing machine capable of producing parts up to 1.5 metres long. Researchers are evaluating which aircraft components can be printed and with which materials. A project conducted with Segula Technologies focuses on manufacturing multi-material energy storage tanks. The laboratory is also in discussions with Airbus and Safran to develop additive manufacturing processes for structural and engine components.

Conclusion

Additive manufacturing is enabling new component designs, higher-performance materials and long-term durability in demanding and strategic environments