A new metal 3D printing technology could revolutionize the way large industrial products like planes and cars are made, reducing the cost and carbon footprint of mass manufacturing.
Why it matters: 3D printing, also called additive manufacturing, has been used since the 1980s to make prototypes and small plastic parts. Metal printing is newer, and the challenge has been figuring out how to make things like large car parts faster and cheaper than traditional methods.
- A new method from a startup called Seurat Technologies, using a powerful laser technique, could be the breakthrough the industry has been waiting for.
- If Seurat’s method can be used on a large scale, America’s fragile supply chains could be reinvented by using low-cost “printing depots” to make parts domestically, in high volume, where and when they are needed. .
Context: Today’s metal 3D printing works by shining a laser onto a thin layer of metal powder, melting it, and welding it to the layer below.
- The digital design gradually takes shape as the layers build up and the object grows.
- However, it is an extremely slow process. Even with multiple lasers, metal 3D printing hasn’t picked up fast enough to produce auto parts and consumer electronics in large quantities.
What’s new: Named for painter Georges Seurat, who studied the science of light and pioneered the style known as pointillism, Seurat’s technology speeds things up by splitting a single high-power laser beam into up to 2.3 million beams. of light.
- A 30 kW laser is modeled with high-resolution images that can be programmed to block or pass light through each of its pixels.
- Each pixel defines its own laser spot, so the system can weld a large area of metal powder in an instant, allowing a multi-layered object to take shape 10 times faster than current 3D printing technology.
- “And it’s not even the beginning of what we can do,” Seurat CEO and co-founder James DeMuth tells Axios.
- Seurat’s technology, he says, is to 3D printing what the printing press was to pen and paper.
The backstory: The idea of pixelating a laser beam dates back to the US Department of Energy’s Lawrence Livermore National Laboratory more than a decade ago, DeMuth writes in a blog post.
- He and other researchers were working on an entirely different problem, power fusion, but the challenge was to design a reaction chamber that could withstand the extreme temperature swings that occur when lasers are used to produce power.
- After much trial and error, they adapted a patterned light method already in development at Livermore Labs for other purposes.
- By 2015, DeMuth and Erik Toomre, co-founder of Seurat, had shown that the technology would also work for metal 3D printing. The company licensed the technology from Livermore Labs in January 2016.
Whats Next: Wilmington, Massachusetts-based Seurat says it has agreements with seven of the world’s largest automotive, aerospace, energy and industrial companies to begin commercializing the technology this year.
- The company has raised $78 million, including a $21 million Series B round extension announced Wednesday.
- Its most recent investors are Xerox Ventures and SIP Global Partners, joined by Capricorn’s Technology Impact Fund, DENSO, True Ventures, GM Ventures, Porsche Automobil Holding SE, Siemens Energy and Maniv Mobility.
Editor’s note: This story was originally published on January 19.
Leave a Reply