3D Systems Secures Additional $9M U.S. Air Force Contract, Bringing Large-Format Metal AM Validation Program to $27.4M with 2-Year Extension
On August 10, 2026, 3D Systems announced an additional $9 million contract award from the U.S. Air Force to continue its GEN-II DMP-1000 large-format metal additive manufacturing advanced technology validation program. Launched in 2023 with an initial contract of approximately $10.76 million, the program has been expanded multiple times to a total value of $27.4 million, with a 2-year extension. R&D is being conducted simultaneously at facilities in San Diego, California, and Rock Hill, South Carolina, with the goal of developing a large-format metal 3D printing system capable of meeting the high-temperature, high-speed, and flight-critical component requirements of aerospace applications.
The Air Force's continued funding increases and program extension signal that early technical achievements have met or exceeded expected milestones—typically, such validation programs are terminated after the initial phase if interim targets are not met. The combination of an extended timeline and additional budget is a strong indicator that the technology's maturity has been recognized.
The GEN-II represents a leap in LPBF (Laser Powder Bed Fusion) from small- to medium-format systems (250–400 mm build volumes) to ultra-large formats (1000 mm+), redefining the "printable boundary" for aerospace structural components. This shift also introduces new demands on the powder supply chain—large-format printing requires significantly tighter control over powder batch consistency, flowability, and oxygen content compared to smaller systems.
Value to powder buyers: ① Ultra-large-format LPBF systems like the GEN-II can consume hundreds of kilograms of powder per single print run; once deployed in procurement, each machine could drive annual powder consumption of tens to hundreds of tons ② Demand for aerospace-grade titanium alloys (Ti64/Grade 23) and nickel-based superalloys (IN718/IN625) is expected to grow significantly ③ Large-format printing demands extremely high powder batch consistency and supply chain traceability, giving certified aerospace powder suppliers a first-mover advantage.
2026-08-10
Xi'an aerospace and Xi'an Jiaotong University jointly achieve high-quality EBSM forming of "unweldable" nickel-based superalloys DZ125/DD6
On August 10, 2026, Xi'an Aerospace Intelligent Manufacturing (a national-level "Little Giant" specialized and innovative enterprise) teamed up with Professor Chen Kai's team at Xi'an Jiaotong University to successfully achieve high-quality, stable forming of DZ125 and DD6 nickel-based superalloys—both highly crack-sensitive materials—using their self-developed M100 electron beam selective melting (EBSM) equipment. The core technology lies in a synergistic control pathway of "high-temperature preheating, melt pool morphology regulation, and scanning strategy matching": a discrete, fixed-point melting scanning approach replaces conventional continuous line scanning, allowing precise control of electron beam melt pool energy.
Validation through CT non-destructive testing, metallographic observation, and EBSD grain structure analysis confirmed that the specimens are free of internal cracks, porosity, lack-of-fusion, and other metallurgical defects, with the ability to achieve directed columnar or equiaxed grain growth as required. DZ125 and DD6 are critical materials for hot-section components such as aircraft engine turbine blades and are widely recognized in the industry as "unweldable" nickel-based superalloys. Traditional precision casting relies on mold cores and suffers from low yield rates, while laser additive manufacturing faces large temperature gradients and difficult-to-control thermal cracking.
This breakthrough provides a new domestic solution for manufacturing integrated aviation hot-section components with thin walls, hollow structures, and multiple cooling channels. The transition from "unweldable" to "high-quality forming" signals that additive manufacturing is challenging the irreplaceable position of traditional casting in the core hot-section components of aircraft engines.
Value for powder buyers: ① DZ125/DD6 powders are high-value-added, aviation-grade superalloy powders; while current annual domestic demand is limited (hundreds of tons), unit prices far exceed those of conventional nickel-based powders. ② The EBSM breakthrough opens new possibilities for powder metallurgy routes to replace precision casting; if scaled to engineering application, it will drive demand for directionally solidified/single-crystal superalloy powders like DZ125/DD6. ③ These specialty powders require extremely high sphericity and purity during production (via PREP or EIGA), and only a few manufacturers have the capability, making this a high-barrier niche market.
2026-08-10
Asia Advanced Materials' Cu15Ni8Sn Beryllium-Free Copper Alloy Powder Achieves SLM Forming with Strength Exceeding 1000 MPa, Positioning It as a Beryllium Copper Alternative
On August 10, 2026, Asia Advanced Materials officially launched a Cu15Ni8Sn pre-alloyed powder produced via vacuum inert gas atomization (VIGA). SLM forming trials have demonstrated a tensile strength of ≥1000 MPa and a hardness of ≥34 HRC, with performance comparable to traditional beryllium copper yet entirely non-toxic and safe throughout the entire process. Leveraging the rapid melting and solidification characteristics of SLM, Sn segregation is suppressed to the micron level—a persistent challenge in conventional casting—while the powder's laser absorptivity exceeds 35%.
The alloy offers superior corrosion resistance (in seawater, acidic, and oil & gas environments) and wear resistance compared to beryllium copper. Its limitation lies in an electrical conductivity of only 9% IACS, making it unsuitable for high-conductivity applications. Target applications include aerospace landing gear bearings and elastic sealing rings, 5G connectors and chip test sockets, marine engineering equipment, and high-load bearings. The Cu-Ni-Sn system is widely recognized by academia as the most promising non-toxic copper alloy alternative to beryllium copper.
This breakthrough underscores the competitiveness of domestic metal powder producers in specialized alloy segments—not as a replacement for commodity powders like 316L or TC4, but as a first-mover advantage in the high-performance copper alloy arena, specifically in the beryllium copper substitution track. Asia Advanced Materials' SLM-ready powder pushes the material to the forefront of industrialization.
Value for powder buyers: (1) With aerospace and electronics industries trending away from beryllium copper due to its toxicity, Cu15Ni8Sn is the leading non-toxic substitute material; its SLM powder form opens up additive manufacturing applications. (2) Target applications such as aerospace landing gear bearings and elastic sealing rings demand extremely high fatigue performance, so subsequent fatigue test data should be closely monitored. (3) With electrical conductivity at only 9% IACS, beryllium copper remains necessary for scenarios requiring both high conductivity and high strength (e.g., resistance welding electrodes); evaluation should be based on specific application requirements.
2026-08-10
