2022 Momentum Newsletter
Product Update

Elementum 3D secures DARPA funding to develop printing process for rhenium metal

Rhenium Metal Printing MaterialElementum 3D has been awarded a Direct to Phase II SBIR contract from DARPA to develop a robust, economical additive manufacturing (AM) process to fabricate complex-shaped components from the refractory metal rhenium (Re).

As a refractory metal, rhenium can withstand high heat and has the 2nd highest melting point of all metal elements behind only tungsten. For this reason, rhenium is sought after as a component material capable of increasing the performance and extending the life of rocket and missile propulsion systems.

While rhenium has significant usage as an alloying constituent in nickel-based superalloys, its use as a base alloy is limited due to difficulty in traditional processing of this material.  Forming rhenium into the complex shapes necessary for these applications is currently costly because of its high melting temperature, and it is an extremely difficult material to machine as it undergoes extensive work hardening. Additionally, some geometries are simply inaccessible with available machining and forming methods. A major initiative of the awarded SBIR is to research and develop an AM fabrication route to print components with geometrical features that cannot otherwise be produced by traditional manufacturing processes including powder metallurgy (PM) and electrical discharge machining (EDM).

As a recognized industry leader in developing new materials and processes for printing complex components using laser powder bed fusion (LBPF), Elementum 3D has a proven track record in developing high quality, repeatable print processes for other refractory metals including tantalum, tungsten, tungsten heavy alloy, and tungsten-rhenium alloy. This experience will allow Elementum 3D to work efficiently and rapidly in establishing a rhenium feedstock supply chain and print process suitable for critical applications.

Elementum 3D’s work on this DARPA project aims to help develop and expand the market for rhenium for AM processing so that the material can be used to benefit a wide range of advanced propulsion and hypersonics applications at the lowest possible cost. Should the base effort prove successful, an “option period” contract may be exercised at DARPA’s discretion to perform component-level fabrication and testing that will help encourage commercial adoption of rhenium for AM.

DFARS 252.235-7010 – Acknowledgment of Support and Disclaimer: This material is based upon work supported by DARPA under Contract No. 140D0422C0003. Any opinions, findings and conclusions or recommendations expressed in this material are those of the author(s) and do not necessarily reflect the views of DARPA.

Elementum 3D and EOS partner to support first collegiate rocket launch

Elementum 3D And Eos PartnerA group of engineering students at the University of Texas at Austin (UT) is striving be the first collegiate team to launch a liquid bi-propellant rocket to an altitude of 100 kilometers, to the Kármán line—the internationally recognized boundary between Earth’s atmosphere and space. To achieve this feat, Elementum 3D and EOS have partnered with the Texas Rocket Engineering Lab (TREL) team to push the limits of science and rocketry with the inclusion of additive manufacturing printer technology and advanced materials.

TREL’s innovative combustion chamber design was printed on an EOS GmbH M 400-1, using Elementum 3D’s advanced copper alloy. This component integrates a special injector design that increases chamber pressure for greater efficiency, and it is fully reusable and able to support up to 60-second firing durations. The choice to use a 3D printing process also allowed the chamber to be printed as a single piece to help guarantee fewer points of failure, enabled special channel geometries to maximize regenerative cooling with a minimal pressure drop, and greatly simplified the manufacturing of unique design capabilities such as regen cooling the lower flange.

TREL views Elementum 3D and EOS as incredibly valuable assets in helping them accomplish their goal to reach the stars with potentially the most efficient 3D printed rocket engine ever produced by a collegiate team!

SPECIAL NOTE: TREL was originally founded to compete in the Base 11 competition. The mission of the competition was to encourage an increased representation of inclusion for women and minorities in STEM. Due to the extenuating circumstances surrounding COVID-19, this challenge—and the $1 million prize—has since been canceled…but that hasn’t stopped the TREL team from propelling forward!

RAM aluminum alloys add competitive advantage to motorsports applications

Ram Aluminum AlloysRacing circuits around the world are enjoying the competitive edge of additive manufacturing (AM). The adoption of our printable high-performance A6061-RAM2 and A2024-RAM2 aluminum alloys are furthering the advantage — both RAM materials have been approved for use in Formula 1 since 2021. Beyond racing applications, we are transitioning our materials to high-end automotive applications — A2024-RAM2 is perfect for high-temperature engine applications and A6061-RAM2 can be used to print a variety of race car components, including brackets, manifolds, rocker arms and additional parts that can benefit from part consolidation or DFAM light weighting. Elementum 3D materials can be purchase through our website. Parameters are included and span a wide variety of printer formats. Contact us today and let’s talk about your application!!
Team News

Join us at RAPID + TCT 2022 to discover what’s possible with metal AM powders

Rapid Tct 2022
Elementum 3D materials experts with be exhibiting at RAPID + TCT on May 17-19 in Detroit, Michigan. We look forward to having investigative conversations with you about revolutionary part designs, application concepts, and solutions to unique AM material needs. Our #1 goal is to help customers take their AM projects to production.

Additional reasons to experience RAPID + TCT 2022:

  1. TAP into North America’s most credible, comprehensive, and influential AM event.
  2. UNITE to share the latest trends in AM with 10,000+ AM professionals
  3. CONNECT with industry innovators as you explore the entire AM ecosystem
  4. DISCOVER solutions at 400+ exhibits
  5. EXPLORE new products – more are launched at RAPID than anywhere else
  6. LEARN from 200+ speakers, hosting 130+ technical presentations
  7. EXPERINCE insights from leading industry keynotes and thought leaders
  8. ATTEND the “AM Industry Celebration” – a can’t-miss networking event – OPEN TO ALL!
  9. DISCUSS Emerging trends with 60+ leaders
  10. INSPIRE others by sharing your story

3D Printing + Aluminum Webinar

Bridging The Gap Live Webinar

Elementum 3D invites you to attend its one-hour co-hosted “Bridging the Gap” webinar on Wednesday, April 27, at 11am (EDT). The third installment of this webinar series will present valuable insights into the capabilities of high-strength aluminum alloys and their impact on critical industrial applications. Technical experts from 3D Systems and Elementum 3D will spotlight exciting new applications and explain how high-strength aluminum alloys and reliable AM processes are meeting the requirements of industry today. An interactive Q&A session will follow.

Key takeaways:

  • Learn why aluminum has emerged as the most desired 3D printing (3DP) metal material.
  • Understand how revolutionary advances in materials development and printer technology have made the near-impossible goal of printing high-strength aluminum alloys possible.
  • See real-world examples of how the availability of advanced aluminum alloys is impacting the advancement of new and innovative applications.
Meet the Experts
Chloe Johnson

Chloe Johnson, Materials Scientist & Aluminums Lead
PhD, Materials Science, Colorado School of Mines
Elementum 3D, Inc.

Jeremy Iten

Jeremy Iten, Materials Scientist & CTO
PhD, Materials Science, Colorado School of Mines
Elementum 3D, Inc.

Aaron Schmitz

Aaron Schmitz, Process & Validation Engineer
3D Systems

Dustin Crouse

Dustin Crouse, Senior Application Development Engineer, Application Innovation Group
3D Systems

Elementum 3D Printing Materials

Elementum 3D exhibits “Live” in Chicago and Detroit

Elementum 3D will be exhibiting its revolutionary technology and materials at two premier annual events showcasing the game changing benefits of AM — Additive Manufacturing Users Group (AMUG), April 3-7, in Chicago, IL (Booth# 68) and Space Symposium April 4-7, in Colorado Springs, CO (Booth# 810). Both events present the perfect opportunity to have our materials scientists, engineers, and sales team onsite to meet AM users face-to-face and gain valuable insights into their materials needs. We are honored to exhibit Elementum 3D’s technology, resources, expert knowledge and experience at both industry leading events.

Additive Manufacturing Users Group
AMUG is a global conference designed for users, by users. The central focused of this event is on accelerating the education and advancement of additive manufacturing and 3D printing. Participating in AMUG offers engineers, designers, managers, and educators from around the world the rare opportunity to share their expertise, best practices, challenges, and application developments in AM with other likeminded users of all commercial additive manufacturing technologies.
37Th Space Symposium
Space Symposium is the premier event for global space professionals. Year after year, the Space Symposium attracts the most influential caliber of participants, exhibitors, and speakers from all sectors of the space ecosystem. Its extraordinary venue and the structure of the agenda create the perfect environment to examine space issues from multiple perspectives, to promote dialogue, and to focus attention on the future of space.

Jamie Perozzi

VP of Technology 6K Additive

Mr. Perozzi has 20+ years of specialty metals experience with a focus on process, new product development, product management, and application engineering. Before joining 6K, Perozzi spent seven years at AMETEK Specialty Metal Products responsible for quality and process engineering. Prior to Ametek, he spent 10 years at Hitachi Metals – Metglas and 3 years at J&L Specialty Steel. Perozzi holds a BS Metallurgical Engineering degree from Penn State University.

Dr. Timothy Smith

Materials Research Engineer NASA Glenn Research Center

Tim Smith graduated with a PhD in materials science and engineering from Ohio State University in 2016. After graduating, his pathways internship at NASA Glenn research center became a full-time position. His research focuses on high temperature alloy development and characterization. He has contributed to 29 peer-reviewed publications including journals in Nature Communications and Nature Communications Materials. His research has also produced 10 new technology reports and 3 utility patents. He recently received both the Early Career Achievement Medal in 2020 and the Exceptional Scientific Achievement Medal in 2022.

Dr. Douglas Hoffman

Senior Research Scientist (SRS)/ Principal Section Technologist NASA Jet Propulsion Laboratory

Dr. Douglas Hofmann is a Senior Research Scientist and Principal at NASA’s Jet Propulsion Laboratory, where he serves as the Section Technologist for the Mechanical Fabrication and Test Section. He is also a Lecturer and Visiting Associate at Caltech in the Applied Physics and Materials Science Department. Dr. Hofmann founded JPL’s Metallurgy Facility in 2010, was a charter member of the Materials Development and Manufacturing Technology Group, and helped establish the JPL Additive Manufacturing Center. He is the Principal Investigator of the NASA FAMIS Flight Experiment and was a 2012 recipient of the Presidential Early Career Award for Scientists and Engineers from President Obama. He has spent more than 12 years working in metal additive manufacturing and has over 30 granted patents and over 60 peer-reviewed publications.

Dr. Jacob Nuechterlein

President/Founder Elementum 3D

Dr. Jacob Nuechterlein is the founder and president of Elementum 3D in Erie, CO. He earned his Bachelor of Engineering, Master of Science, and Doctor of Philosophy at the Colorado School of Mines. Jacob has been researching, teaching, or consulting on topics such as casting and powder metallurgy for the last 14 years. Elementum 3D’s work with powder bed laser additive manufacturing is based on these principles. In addition, is thesis work in thermodynamics and formation kinetics of metal matrix composites is directly related to all 3D printing processes.