6K Additive has been selected to join forces with the RTX Technology Research Center (RTRC) and the University of Arizona in the Environmental Additive Research for Tomorrow’s Habitat (EARTH) project, managed by America Makes and the National Center for Defense Manufacturing and Machining (NCDMM). This project is dedicated to creating environmentally-friendly production techniques for aerospace and defense parts using additive manufacturing.
Backed by $1.2 million from the Office of the Under Secretary of Defense, the EARTH Project intends to transform the manufacturing of aerospace and defense items. 6K Additive’s involvement will focus on using advanced mode-guided process development, innovative laser optics, and enhanced powder feedstock to refine Ti-6Al-4V—a widely utilized titanium alloy. The project’s objectives include boosting deposition rates, augmenting feedstock reuse, and enhancing recyclability, alongside performing techno-economic and lifecycle analyses to validate the sustainability advantages.
The EARTH project’s ambitious targets comprise a doubling of metal additive manufacturing deposition rates and slashing the energy needed for feedstock production by at least 75%, while ensuring no compromise on component quality. 6K Additive aims for a 50% reduction in the overall energy usage required to produce additive components.
Brian Fisher, the lead researcher for the Powder and Process Optimization for Sustainable Additive Manufacturing (POSAM) initiative at RTX, highlighted the significance of adopting sustainable methods in advanced aerospace and defense manufacturing. Fisher stated, “Our strategy is to roll out hundreds of new additively manufactured components in the coming years. We have partnered with 6K Additive because they excel in transforming discarded and used powders into high-grade, valuable materials. This not only addresses quality and ecological impact concurrently but also reduces production costs at large scales.”
The proactive strategy of POSAM, coupled with meticulous impact evaluations, is poised to hasten the integration of additive manufacturing throughout the Department of Defense (DoD) supply lines. This project demonstrates the ability of the POSAM method to enhance printing speeds, lower energy use, and streamline intricate logistical frameworks, thereby promoting cost-effective and eco-friendly manufacturing solutions.
6K Additive is recognized as the premier manufacturer globally of additive manufacturing powders sourced from sustainable materials. Their product lineup includes powders made from nickel, titanium, copper, stainless steel, aluminum, and other specialty metals like tungsten, niobium, and rhenium.
Endorsed by the UniMelt microwave plasma technology, which operates at a production-scale, 6K’s method meticulously rounds metal powders and simultaneously maintains tight control over the chemical composition and porosity of the end product. This technique prevents any contamination and supports high-volume production, marking 6K’s prominence in the field.
According to a recent Life Cycle Assessment (LCA) study, 6K’s approach can achieve remarkable reductions in energy usage and carbon emissions. For its nickel-based alloys, the company reports a 90% reduction in both energy consumption and carbon footprint, while titanium alloys see a 75% reduction. These achievements underscore 6K Additive’s dedication to driving sustainability in additive manufacturing and supporting the broader goals of the EARTH project.
Source: engineering.com
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