Breakthrough in Multi-Metal 3D Printing: ETH Zurich Students Develop Novel Advanced Process

Zurich, Switzerland, September 10, 2025 – A talented team of students at ETH Zurich has achieved a significant breakthrough in the field of metal additive manufacturing, developing a novel multi-metal 3D printing process. The laser powder bed fusion machine they constructed not only allows for the processing of multiple metals in a single operation but also significantly reduces manufacturing time and material waste. This achievement, announced on September 9, 2025, promises to revolutionize how complex metal parts are produced, especially in demanding industries such as aerospace, energy, and mechanical engineering. For investors, managers, and technical experts, this is a clear signal of the immense potential of additive manufacturing technology in shaping the future of the metal industry.

Novel Machine Design and Multi-Metal Capability

The core of this innovation lies in the printer's unique design. Unlike traditional layer-by-layer systems, this machine utilizes a continuously rotating build platform. Metal powder is continuously applied and melted by a laser following a circular tool path. This continuous process offers several benefits:

• Reduced Production Time: By eliminating the waiting time between layers, the process significantly accelerates manufacturing speed.
• Simultaneous Multi-Metal Capability: The system can process two different metals (e.g., copper and nickel alloys) simultaneously in a single manufacturing step. This allows for the creation of parts with graded thermal and mechanical properties tailored to specific application needs – for instance, high thermal conductivity on the inside and high heat resistance on the outside. This is an extremely critical advantage for applications such as rocket nozzles and turbomachinery components.

Advanced Process Control and Potential Applications

To ensure the quality and integrity of the printed parts, the student team developed a specially designed inert gas flow system. This system blows inert gas over the melting area to prevent oxidation and remove unwanted byproducts (soot, spatter). Tight control of gas flow conditions and synchronization of the laser, powder feed, and gas supply were critical technical challenges successfully addressed by the team.

This technology opens the door for manufacturing parts with complex geometries and customized material properties, which are difficult or impossible to achieve with traditional manufacturing methods. Potential applications include:

• Aerospace: Rocket nozzles, engine components with high-temperature and durability requirements.
• Energy: Gas turbine components, high-efficiency heat exchangers.
• Mechanical Engineering: Machine parts with material zones optimized for specific functions.

Rapid Development and Commercialization Prospects

Remarkably, this machine was designed, built, and tested within just nine months by a team of six Bachelor's students under the supervision of Professor Markus Bambach and Senior Scientist Michael Tucker at ETH's Laboratory of Advanced Manufacturing Technologies within the RAPTURE Focus Project. Many parts had to be custom-engineered due to the lack of commercially available alternatives.

The current prototype is capable of producing components up to 20 cm in diameter. ETH Zurich plans to scale this technology for larger parts and higher speeds. The team has filed a patent and is actively seeking industrial partners to commercialize this technology for applications in aerospace, mechanical engineering, and energy. This demonstrates the immense potential of this technology to transition from research to practical industrial application.

Far-Reaching Impact on the Metal Industry

This innovation promises to make multi-metal 3D printing, which has traditionally been complex and expensive, more accessible to smaller operators. By reducing time, cost, and material waste, this process can drive wider adoption of metal additive manufacturing across various industries. It also unlocks new possibilities for product design, allowing engineers to create parts with optimized performance that were previously unattainable.

In an industrial landscape increasingly seeking more efficient and sustainable manufacturing solutions, this technology could play a crucial role. It complements advancements in other materials, such as aluminum – the material for modern and future industries, by offering a novel method to combine the unique properties of different metals into a single structure.

Conclusion

The development of this novel multi-metal 3D printing process by ETH Zurich students is a strong testament to the power of innovation and research in driving technological progress. With its ability to produce complex parts with customized material properties more efficiently, this technology has the potential to reshape supply chains, unlock new design opportunities, and enhance the competitiveness of critical industries. Investors and technical experts should closely monitor the development of this technology, as it could be a game-changer in the field of metal additive manufacturing.

References:

• EEJournal (2025). Students develop novel multi-metal 3D printing process. news/students-develop-novel-multi-metal-3d-printing-process/"">https://www.eejournal.com/industrynews/students-develop-novel-multi-metal-3d-printing-process/
• ETH Zurich (2025). Students develop novel multi-metal 3D printing process. https://ethz.ch/en/news-and-events/eth-news/news/2025/09/students-develop-novel-multi-metal-3d-printing-process.html
• 3DPrintr (2025). ETH students develop 3D printing machine for multi-metal components. https://www.3printr.com/eth-students-develop-3d-printing-machine-for-multi-metal-components-4183445/
• VoxelMatters (2025). ETH students develop novel rotational multi-metal 3D printing process. https://www.voxelmatters.com/eth-students-develop-novel-rotational-multi-metal-3d-printing-process/