July

2021 Momentum Newsletter
Product Update

Elementum 3D adds SPEE3D’s cold spray AM technology

On July 27, 2021, Elementum 3D announced the acquisition of a SPEE3D cold spray metal 3D printing technology. With the addition of a WarpSPEE3D metal 3D printer, we now have the latest tool for advancing our current additive manufacturing (AM) capability.

The WarpSPEE3D is SPEE3D’s large format cold spray metal 3D printing machine able to build multiple components at once up to 1000mm x 700mm in diameter. It has the capacity to print 30 tons of metal parts per year and is 100 to 1000 times faster than traditional metal 3D printing methods. The WarpSPEE3D system uses supersonic jets of metal powder to fuse material through a kinetic-to-thermal energy transformation.

SPEE3D cold spray metal 3D printing technology

“We are very excited about partnering with such a pioneering company such as Elementum 3D.  Their additive manufacturing and material expertise will help to bring Cold Spray Additive Manufacturing to the forefront and quite literally change the way parts are manufactured in several industries,” states Byron Kennedy, CEO of SPEE3D.

The acquisition enables Elementum 3D to offer a rapid and cost-effective cold spray solution for customers who require large, high-quality metal AM parts for applications such as Defense, mining, oil and gas, aerospace, automotive industries, and more.

“We are confident the acquisition of SPEE3D’s technology will be an excellent addition to our current capabilities. Developing and applying Elementum 3D materials to SPEE3D’s cold spray printers is a major step forward towards our goal to offer customers a comprehensive range of AM solutions,” stated Dr. Jacob Nuechterlein, CEO of Elementum 3D.

FULL ARTICLE

Elementum 3D printing materials

Why are print parameters included with
Elementum 3D powders?

Elementum 3D provides printing parameters with the purchase of Elementum 3D powders because they are the most important factor to increasing efficiency when 3D printing a high quality component. Printing parameters provide the processing information required to coordinate the printing of a component using a 3D printer, equivalent to the instructions required to bake a cake!

3D printing with Parameters

For over six years Elementum 3D has honed its expertise in developing advanced high-performance AM materials along with the parameters required to print them. The development and maintenance of our material parameters are regularly reviewed and updated for all Elementum 3D-approved laser powder bed fusion printers and others. This practice ensures the end user will consistently print high quality components.


Given the importance of parameters, it is amazing how often AM powders are sold without parameters. A primary reason for extended delays in 3D printing is from not having parameters available. When parameters are not provided end users will most likely experience difficulties achieving expected material properties and consume a great deal of time using inefficient trial-and-error techniques.

Inclusion of printing parameters with all Elementum 3D materials is just one of the ways we are making additive manufacturing more attractive to manufacturers. Another is providing heat treatment schedules (included when necessary)!

Elementum 3D printing materials
Photo Credit: JPL

NASA JPL test A6061-RAM2 parameters

JPL has advanced new alloy qualification to a new frontier with the printing of a scaled-down model of the Mars Perseverance rover wheel.  While many from several industries have designed and printed various components to test A6061-RAM2 parameters, the JPL printing of the rover wheel is a first. Their attention to detail is impressive. They included flexures in the suspension design and the grousers are straight, making it clear that this is the wheel from Perseverance.

While this is a test component, we are nevertheless excited to see that JPL is researching new additive manufacturing alloys for future space travel applications.

Team News

Elementum 3D team building in the mud!

Elementum 3D Team Building

On July 24, twenty Elementum 3D employees came together to compete in the “Tough Mudder” event. Together they accomplished it!

This was not a social distancing event. The “Elementum 3D TOUGH” team had to establish trust, communicate efficiently, and — most of all — lend a helping hand to conquer the 10-mile course that included 24 grueling and muddy obstacles. 

Getting muddy together proved to be a fun way to build connections with teammates from different departments, improve company morale, and inspire some friendly competition. 

Elementum 3D printing materials

Employee update

July 2021 NEW HIRES

Kevin Eckes, PhD – Research Scientist

Kirk Wyman – HR Manager

 

July 2021 PROMOTION

Heidi Meador – Analytical Lab Manager

 

CURRENT JOB POSTINGS

Chief Operating Officer (Full-time)

Engineering Lab Technician I (Full-time)

Additive Manufacturing Technician (Full-time)

CAD Technician (Full-time)

Elementum 3D Staff Updates
Last Month's Articles

Two SBIR Phase I grants awarded Elementum 3D

In May 2021, NASA awarded a SBIR Phase I grant to Elementum 3D. The SBIR is centered around the development of additively manufactured soft magnetic materials for large diameter Hall-effect thrusters. In-space electric propulsion systems are of growing importance for interplanetary missions and better manufacturing methods are needed to produce large diameter Hall-effect thrusters with the right magnetic properties and structural robustness. 

6kw Hall thruster in operation at the NASA Jet Propulsion Laboratory

We are honored to work with NASA and partner Altius Space Machines in developing AM iron-cobalt alloys, printing processes, and post processing to achieve the needed performance for Hall-effect thrusters and other space and terrestrial uses.

Elementum 3D printing materials

In June 2021, the Department of the Navy awarded Elementum 3D a contract for their Phase I SBIR project “Controlling Microstructure Through Nucleation – The Key to Designing the Next Generation of High-Performance Alloys for Additive Manufacturing”. 

Controlling Microstructure Through Nucleation - The Key to Designing the Next Generation of High-Performance Alloys for Additive Manufacturing

Working together with Dr. Jonah Klemm-Toole at the Colorado School of Mines and Special Aerospace Services, Elementum 3D will develop a modeling framework linking alloy chemistry, AM processing, thermal history, microstructure and defect development and mechanical properties. Elementum 3D’s rapid experimental alloy development (READ) process will be used to provide extensive experimental validation of the model predictions to allow for iterative model development and improvements. The validated model will then be used as a guide for development of new designed-for-AM nickel superalloys, copper alloys, and more.

Elementum 3D printing materials

Data sheet updates

AM Material Data Sheet - Elementum 3D

In order to provide the best customer service, we are pleased to announce that we have recently posted updated data sheets. We invite you to visit the Elementum 3D “Data Sheets” web page obtain to the most up-to-date data points and charts.

Elementum 3D printing materials

U.S. Navy high-tech challenge recognizes A6061-RAM2 as metal AM solution

Elementum 3Ds A6061-RAM2 bracket

On June 2, 2021, Elementum 3D was an award winner in the “Heavy Metal” track of the Navy’s “HacktheMachine Challenge.” The challenge included hundreds of participants, across the Navy enterprise, as well as those in the public and private sectors. The event’s goal was to solve some of the Navy’s most high-tech challenges in a three-track prize challenge called “HACKtheMACHINE” — hosted by Naval Sea Systems Command (NAVSEA).

Elementum 3D surpassed all other materials development contestants in the “Heavy Metal” track, a hybrid virtual and physical challenge that allows the Navy to tap into a wider and more diverse base of advanced manufacturing in this country and beyond. Elementum 3D’s A6061-RAM2 part was entered in the main Heavy Metal track challenge, entitled “Light It Up,” which consisted of converting an existing 2D drawing of a standard bracket that connects a light fixture to a stanchion into an innovative 3D printed part. The printed bracket was then submitted for evaluation, which included vibration and shock testing.

Innovations created through Heavy Metal track challenge will accelerate the adoption of metal additive manufacturing (AM) in the U.S. Navy and support their initiative of bringing innovative processes and technologies directly those who need it. “At sea, if I have a part fail – I need to be able to print as much of that part as I can while at sea,” said Rear Adm. Jason Lloyd, U.S. Navy, Naval Sea Systems Command, Chief Engineer and Deputy Commander for Ship Design, Integration and Naval Engineering.

Elementum 3D is honored to be acknowledged by the Navy as a leader in the AM community and we look forward to utilizing our technology and expertise to strengthen the Navy by partnering with them to overcoming current and future advanced manufacturing maritime challenges.

Elementum 3D printing materials

Cool Part Show showcases A1000-RAM10

On May 12, 2021, “The Cool Parts Show” broadcasted their 30th episode, “Lightweight Combustion Chamber Part of 3D Printed Rocket Engine.” It featured Masten Space Systems lightweight, reusable combustion chamber design for NASA’s “Broadsword” rocket engine printed by Elementum3D with Elementum 3D’s aluminum metal matrix composite (MMC) product — A1000-RAM10. 

Masten’s chamber fires successfully for two reasons, its innovative design and because it is printed out of our A1000-RAM10 product, allowing for the much-desired material that combines lightweight aluminum with the high temperature performance of ceramic.

NASA plans to fly repeated trips to the moon with the rocket engine, in rapid sequence with little delay between launches.

In addition, we were featured in its 27th episode, Lighter, Better-Performing Brake Rotor From 3D Printing: The Cool Parts Show #27. It was originally broadcasted live and centered around Ceramic Disc Technology for a Dodge Challenger Hellcat. See how Elementum 3D and Ceramic Disk Technologies (CDT Rotors) combined their revolutionary technologies to eliminate two-thirds of the rotor’s mass, deliver five times the thermal conductivity and reduce brake dust by 95% compared to the car’s standard rotor.

In addition, we were featured in its 27th episode, Lighter, Better-Performing Brake Rotor From 3D Printing: The Cool Parts Show #27. It was originally broadcasted live and centered around Ceramic Disc Technology for a Dodge Challenger Hellcat. See how Elementum 3D and Ceramic Disk Technologies (CDT Rotors) combined their revolutionary technologies to eliminate two-thirds of the rotor’s mass, deliver five times the thermal conductivity and reduce brake dust by 95% compared to the car’s standard rotor.

Elementum 3D printing materials

H.E.A.R.T centered for success

HEART by Elementum 3D

To serve our customers with world-class products and services, we recognize that it starts with our values, norms, attitudes, and beliefs. Recently, senior management established three core E3D values: Honor, Expertise and Revolutionary (AKA “The HEART of E3D”), to publicly set a precedent for excellence.   

Establishing a value system that is H.E.A.R.T centered will house the right overarching leadership behaviors and actions to support our customers lofty goals. Collectively, Elementum 3D team members have a clear understanding of who we are and what we stand for in order to inspire the end user to greater achievement in additive manufacturing (AM) with long-term, sustained success.

Now that we have solidified our three core corporate values, let’s break each value down to understand how they directly impact our interactions with the AM community.

Honor

Building our culture based on high respect, high moral standards of behavior starts from within. We recognize that a unified, deeply committed, and interconnected team will form a company that will be forever known as a caring, authentic, and ethical organization that can be trusted.

Expertise

Elementum 3D was founded on educating our customers. We are dedicated to help solve their problems or at least narrow the options by asking in-depth questions and providing relevant data to point them towards a solution that is in the customer’s best interest.

Revolutionary

This vital corporate value identifies us as the leader in metal AM materials development, moreover, it signifies two truths to the entire manufacturing industry: 1. E3D is a stable and reliable entity and 2. Our tireless pursuit to revolutionary thinking brings to market the availability high-quality groundbreaking products and services enabling end-users to reap the design freedoms of additive manufacturing.