Elmet Technologies Deploys 3D Systems DMP Flex 350 Triple

Elmet Technologies, a subsidiary of The Elmet Group, is deploying 3D Systems’ DMP Flex 350 Triple laser powder bed fusion platform for the production of advanced aerospace components for hypersonic vehicles. The metal additive manufacturing system utilizes a high-performance C103 niobium-based alloy to fabricate large heat exchangers, targeting system qualification and production startup in 2026.

Material Processing Parameters and Alloy Characteristics
Elmet Technologies developed processing parameters for the C103 material over an eight-year period in collaboration with 3D Systems’ Application Innovation Group (AIG). C103 is a refractory alloy composed primarily of niobium combined with hafnium and titanium, engineered for high-temperature aerospace applications.

Scott Ohm, R&D Manager at Elmet Technologies, stated that the initial parameter development was conducted on an earlier 3D Systems metal printer, establishing a research foundation intended to facilitate production setup on the DMP Flex 350 Triple.

Machine Architecture and Production Capabilities
The DMP Flex 350 Triple features a 350 x 350 x 350 mm build volume and incorporates a three-laser array to increase production throughput. The machine operates with a sealed build chamber that maintains an internal oxygen concentration below 25 ppm, typically operating between 0 and 6 ppm.

This low-oxygen architecture prevents contamination of reactive and refractory metals during laser melting, supporting material reuse rates, chemical composition control, and surface finish consistency. Elmet Technologies selected the platform to support large build requirements, rapid production volumes, in-house material processing, and specialized heat exchanger manufacturing.




Qualification Timeline and Aerospace Certification
Elmet Technologies expects to complete machine, material, and process qualification within a couple of months, followed by NASA 6030 certification several months later.

Scott Ohm noted that achieving NASA 6030 certification shortly after system qualification demonstrates the quality of the overall solution and validates the collaborative approach taken with 3D Systems' aerospace experts to streamline validation timelines.

Mike Shepard, Vice President of Aerospace & Defense at 3D Systems, stated that the low-oxygen architecture of the DMP series is suited for manufacturing complex components from reactive metals such as C103 and other refractory alloys.

Supply Chain Integration and Monolithic Manufacturing
Direct Metal Printing (DMP) allows the production of monolithic metal structures with complex geometries, thin walls, increased surface-to-volume ratios, and optimized heat transfer capabilities with controlled pressure drop characteristics. Compared to legacy manufacturing methods such as brazing, additive manufacturing reduces assembly steps, lead times, production costs, and supply chain dependencies while improving component yield and reliability.

Integrating in-house refractory materials with the DMP Flex 350 Triple allows Elmet Technologies to establish localized, tool-free production of defense and aerospace components for the U.S. defense industrial base.

Edited by Romila DSilva, Induportals Editor, with AI assistance.