
Additive Manufacturing
Rely on EWI’s expertise in design for additive manufacturing (AM) and implementation of innovative 3D manufacturing solutions.
Multi-material and metal additive manufacturing techniques have evolved for decades, moving beyond prototyping to mainstream use. EWI helps clients across industries apply 3D printing and large-scale AM technology to industrial production.
Today, companies use additive manufacturing technology to build products and components that were previously impossible – single pieces made from multiple materials with no joints. AM also offers novel approaches to reducing part count, making on-site repairs, reconstructing hard-to-find or obsolete parts, reducing material costs, minimizing waste, and improving speed-to-market through streamlined production.
The technology’s potential is immense, exciting, and still emerging. If you’re ready to put it to good use, connect with EWI’s engineers to design, develop, and implement your additive manufacturing solution.
Additive Manufacturing Consulting and Hands-On Technology Development
EWI supports the broad adoption and optimization of advanced metal 3D printing and large-scale additive manufacturing (LSAM) technologies in all industrial sectors. We have expertise in all seven AM process categories defined by the ASTM and specialize in metal process development, including powder and wire feedstocks. Our comprehensive approach helps clients address development needs, solve additive manufacturing engineering problems, and meet implementation goals.
Our multi-material and metal additive manufacturing services include:
- Additive manufacturing process development and qualification based on your applications
- Materials selection, characterization, and database development
- Product design for AM (DfAM), from micro- to large-scale
- Custom additive manufacturing tooling and equipment development
- Additive prototyping
- In-process monitoring and sensing
- Component post-processing
- Post-process additive manufacturing inspection
- Manufacturing Digital Thread and convergent manufacturing
- Offline programming for all AM modalities
- Process and machine characterization
We’ll assist you at any stage, or all stages, of the technology rollout process: setting product requirements, modifying AM designs, qualifying feedstock, validating processes, and (if needed) identifying an additive manufacturing company to print at scale.
Why Choose EWI’s Additive Manufacturing Experts?
EWI has been at the forefront of additive engineering and process integration for more than 40 years. Because the 3D printing process is an extension of the conventional joining processes that established our company, applied R&D in additive manufacturing naturally aligned with our experience and core technologies. For example, our deep experience with friction stir and ultrasonic joining processes has helped us develop novel large-format additive manufacturing technologies, and our arc and laser welding process history has been producing cladding layers and buildups for decades. Our deep expertise in each joining process and the fundamental material science allow EWI to provide value to both clients and Consortium participants.
Our additive manufacturing experts draw from EWI’s broad expertise in welding and joining, materials science, process sensing and controls, nondestructive evaluation, modeling, structural mechanics, and automation. Whether we’re providing full-service design for additive manufacturing or consulting on a single process adjustment, we’re innovators of 3D manufacturing technology across industries. As a result, we’re more than just problem solvers; we offer extensive services in AM.
See Us in Action
Identify.
Develop.
Implement.
WE MANUFACTURE INNOVATION.
EWI leads the way in additive manufacturing by evaluating new processes, developing material property data, and helping our clients adopt and implement state-of-the-art technology to build their products. We’re ready to move your operation forward with AM.
With extensive expertise in materials joining and deposition, including all supporting processes, EWI can support manufacturers through all stages of technology development and implementation.
Need some help?
EWI’s AM Working Groups
EWI operates the Additive Manufacturing Consortium (AMC) to share thought leadership, conduct collaborative sponsored projects, and solve common challenges in multi-material and metal AM.
EWI is a founding partner of the ASTM Additive Manufacturing Center of Excellence. The center bridges AM standards with R&D to enable efficient development of standards, education and training, certification, and proficiency testing programs.
Technical Expertise
- Process and application expertise
- All powder bed fusion processes
- All directed energy deposition (DED) processes
- Solid-state AM processes
- Cold Spray
- Ultrasonic AM
- Large-scale additive manufacturing
- Materials and process development
- In-process sensing and quality control
- Post-process nondestructive inspection (UT, EC, X-ray CT)
- Qualification, certification, and design allowable generation
- Metallurgy
- Powder characterization
- Heat treatment development
- Property databases
- Powder production/modification
- Machine design and build
- Design for additive manufacturing processes and materials
Equipment & Lab Resources
Fully equipped labs across two EWI facilities support powder and surface characterization, metallurgical characterization, mechanical testing and NDE, powder production, X-ray computed tomography, and space for large-scale deposition work.
Resources include:
- Objet Connex J750
- LPBF
- EOS M290
- Wayland Calibur3
- Navus JR
- Navus Gantry
- Arcam A2X
- Sciaky EBAM 110
- RPM 557
- Fabrisonic SonicLayer 7200
- Meld L3 AFSD
- EWI-designed-and-built open architecture laser powder bed fusion for sensor evaluation
- Arc deposition robotic work cells
- Robotic ABB, Fanuc, Yaskawa Motoman, Cloos, OTC, Fronius, Lincoln, ESAB, Miller, OTC, Cloos
- Laser deposition robotic work cells:
- Haas, Aerotech, Yaskawa Motoman, Trumpf, IPG, Laserline, nLight, Fraunhofer, Dinse, Medicoat
- ExOne Innovent
- X-ray CT, UT, ET