Metal 3D printed substrate can be reused

While 3D printing technology offers remarkable scientific and technological advancements, the high cost of consumables often drives up production expenses. To cut costs and improve resource efficiency, companies can take a leading role in adopting sustainable practices. A recent breakthrough from the Open Sustainable Technology (MOST) lab at the Michigan Institute of Technology highlights an innovative approach to reducing waste in metal 3D printing. The research team, led by Amberlee S. Haselhuhn, Bas Wijnen, Gerald C. Anzalone, Paul G. Sanders, and Joshua M. Pearce, published a paper titled *"In Situ Formation of Substrate Release Mechanisms for Gas Metal Arc Welding Metal 3D Printing."* This study focuses on improving the substrate removal process in metal 3D printing, proposing a reusable substrate system that could significantly lower costs and environmental impact. Gas Metal Arc Welding (GMAW) is a cost-effective method for metal 3D printing, where a metal wire is fed through a nozzle and melted using an electric arc between the wire and the substrate. The researchers developed an open-source 3D printer tailored for GMAW, using a three-axis table to hold the substrate while the welder deposits layers of aluminum or steel. However, the final object tends to bond strongly to the base, making it difficult to remove without damaging the part. To solve this issue, the team designed a release mechanism that allows the printed object to be easily separated from the substrate without compromising its structural integrity. This innovation not only enhances the reusability of the substrate but also supports more sustainable and efficient manufacturing processes. By enabling the reuse of substrates, this approach reduces material waste and lowers the overall cost of metal 3D printing, making it a promising development for industries looking to adopt greener technologies.

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