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Metal Additive Manufacturing Case Studies

  • Close up of 3D printed Gear Box Housing and Heat Exchanger

    R&D project gives 100% production quality assurance

    3T’s latest R&D project aims to give customers 100% production quality assurance in their metal 3D Printed parts by developing an automated non-destructive inspection process to identify any internal or external defects such as porosity, internal cracks, microstructural defects and trapped powder, along with their location …

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  • Featured Image

    Titanium Glasses using Metal Additive Manufacturing

    Eye Venture Ltd is using 3T’s metal Additive Manufacturing services to produce lightweight frames for their Aviator and Navigator styles in Titanium. Based in New Zealand, they are proud to have them ‘Made in England’ and have a solid partner for their exclusive eyewear range …

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  • E-box in titanium using metal AM

    AM reduces production steps, lead time and cost

    Using metal AM, we produced a new “E-Box” resulting in a reduction in the number of production steps from 38 to 9 and lead time reduced from 20 weeks to 5 weeks. Furthermore, the cost of the component was reduced by more than 30% ...

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  • Bike Stem on Metal AM build platform

    Lightweight Bike Stem using metal AM

    As a partner in the TSB funded SAVING Project, we built a bike stem with a complex internal lattice structure to reduce its weight whilst maintaining its aero dynamicity and strength ...

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  • Post Operation X Ray Of Implanted Stem

    Superior fixation for implant using AM

    Having identified that inadequate primary (immediate) and secondary (long-term) fixation is a major factor in loosening, and thus failure of, orthopaedic implants, The Biomechanics Research Centre at National University of Ireland, Galway (NUI Galway) developed OsteoAnchor technology. This is an optimised surface architecture for an implant incorporating a multitude of tiny claw features which embed into the patient’s bone during implantation ...

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  • Titanium mandibular implant for QMC patient

    Titanium mandibular implant for QMC patient

    A patient at Queen’s Medical Centre in Nottingham had significant facial asymmetry leading to functional problems and aesthetic issues. The surgical team wanted to improve both areas and looked to produce an implant (alloplastic facial implant). In the past, a number of materials and techniques have been used for such implants, however all have limitations.

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  • Titanium F1 Roll Hoop proves concept

    Titanium F1 Roll Hoop proves concept

    Since 2009, 3T RPD have been gaining experience in building structural components for the Formula 1 motorsport sector. Of these types of parts the rear roll hoop structure is one of the largest and most demanding from the point of view of Additive Manufacturing (AM). However, for each of the teams we work with, this safety critical item is also one of the most important and therefore any work that has been carried out has to be kept strictly confidential. This poses the daily problem for 3T of how to demonstrate the kind of work that is possible in AM, whilst also maintaining customer confidentiality.

  • Gear change hydraulic actuator system

    Gear change hydraulic actuator system

    Designed for electronic twin-clutch gear change in a high-performance vehicle, the original gear change hydraulic actuator system was machined from two aluminium blocks and assembled using bolts. The hydraulic pathways were conventionally drilled and plugged, creating multiple right-angle bends. The brief was to review the part and redesign it to take advantage of the benefits of additive manufacturing.

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  • SAVING Project - saving litres of aviation fuel

    SAVING Project – saving litres of aviation fuel

    The SAVING Project wanted to take a conventional part, redesign it to take advantage of the benefits of Additive Manufacturing thereby reducing its weight, in order to demonstrate the potential energy saving possible during the product’s lifetime use.

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  • Personalisation of Titanium part

    Personalisation of Titanium part

    The tie clip was built in Titanium on an M280. The M280’s 400 watt laser meant the clip was built faster and with finer detailing than previous DMLS machines.

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