ALD introduces the EBuild 850: Large-format metal 3D printing with a focus on electron beam technology

In recent years, additive manufacturing processes have evolved from specialized applications into an integral part of industrial production chains. In addition to prototypes, near-series components are increasingly being produced, particularly where design freedom and material efficiency are required. Against this backdrop, ALD Vacuum Technologies GmbH has introduced the EBuild 850, a new system for electron beam–based metal 3D printing designed for large-volume applications.

The system operates on the principle of Electron Beam Powder Bed Fusion and combines a build volume of 850 × 850 × 1,000 millimeters with a high build rate. The aim is to manufacture even complex and massive components in a continuous process. Compared to subtractive methods, the component is created layer by layer by locally melting metal powder. This significantly reduces material consumption while simultaneously enabling new degrees of freedom in design.

“Instead of removing material as in milling, components are built up layer by layer by selectively melting raw material with a powerful energy source, such as a laser or an electron beam,” explains Dr. Alexander Klassen, Vice President Additive Manufacturing at ALD.

Technically, the EBuild 850 is based on a high-performance electron beam gun with a movable build chamber and a specially developed powder application system. This system is designed to reliably process even powders with poor flow characteristics. An optional second build chamber allows setup and cooling times to be decoupled from the actual manufacturing process, increasing machine availability. The precise positioning of the powder bed carrier over the entire build height is designed for high repeatability.

“To deliberately overcome limitations in component size, we significantly expanded the chamber design—without compromising process stability,” explains Dr. Klassen. “For our customers, this not only means a substantial increase in productivity with consistent quality, but also opens up entirely new dimensions for alternative processing strategies and shorter lead times.”

Another key focus is the efficient handling of metal powder. The system can also process powders with a broader particle size distribution, including surplus material from ongoing production or batches outside tight specifications. This reduces material costs and supports closed powder loops. The concept is complemented by integrated process monitoring, in which the electron beam is also used to analyze each individual layer.

With the EBuild 850, ALD addresses applications that require large-format metal components, high process temperatures, and reproducible quality. This illustrates how metal 3D printing continues to evolve toward industrial series production.