Fluent Metal, a U.S.-based company, has pioneered a sophisticated metal 3D printing process that employs a drop-on-demand method to fabricate parts with precision and efficiency. This process relies on ultra-fine wires to deposit material in precisely controlled droplets, offering a streamlined alternative to traditional powder- and laser-based methods. The system is designed for flexibility, making it suitable for both prototyping and production-scale applications across various industries. In an interview with 3Druck.com, CEO and founder Peter Schmitt details how Fluent Metal’s technology can address a variety of industrial challenges.
One of the key features of the droplet-based technology is its compatibility with a wide range of metals, including copper, silver, stainless steel, tungsten, and other specialized alloys. This broad material support makes the technology adaptable to diverse use cases, from aerospace and defense to consumer goods such as jewelry and electronics. The ability to switch materials easily further enhances its versatility.
Unlike many conventional methods, Fluent Metal’s wire-based approach eliminates the need for metal powders, reducing material waste and energy consumption. This not only lowers operational costs but also simplifies the manufacturing process. Additionally, the absence of lasers and powders increases safety, allowing the system to operate in standard production environments without requiring special protective measures.
The technology’s scalability and precision ensure consistent quality across various production stages. The company’s process also minimizes variability and can handle parts of a wide range of sizes, making it a practical solution for both small-scale and large-scale manufacturing. With recent funding of $5.5 million to advance its development, Fluent Metal is well-positioned to enhance its innovative technology, accelerate the commercialization of its 3D printing systems, and address key challenges in metal additive manufacturing, including efficiency, scalability, and material versatility, paving the way for broader industrial adoption.
Interview with Peter Schmitt
In the interview with 3Druck.com, CEO and founder Peter Schmitt discusses Fluent Metal’s innovative drop-on-demand metal 3D printing technology and its potential applications across industries. He highlights the system’s advantages over traditional methods and outlines the company’s progress, including current pilot projects and plans for beta machine development.
What inspired the initial concept to develop a liquid metal drop-on-demand technology and how did it evolve into the current system?
Peter Schmitt, Image Credit: Andy Ryan
Prior to founding Fluent Metal, I’d spent a number of years in the 3D printing industry, including as Chief Designer at Desktop Metal. It was clear there were steep limitations in existing metal additive manufacturing methods: they required extensive infrastructure, posed substantial safety concerns, and resulted in significant material waste. We recognized the need for a system that could eliminate these barriers while expanding the utility of additive metal manufacturing.
Our thesis was that droplet-based deposition (similar to inkjet printing, but for metals) could potentially offer precise control without the waste and expense of powder-based systems. We focused on developing an approach that could use standard metal wire as feedstock, eliminating the complexities of powder handling and enabling operation in standard workshop environments.
What features of your technology ensure precise and consistent results for complex geometries, and how does it compare to traditional metal additive manufacturing methods?
Our technology achieves precise and consistent results through plasma-based melting of the wire tip for controlled droplet formation, ensuring precise droplet positioning, and a single-step, parallelizable process that scans the print bed and is massively scalable.
Compared to traditional powder-bed systems, our approach offers several advantages:
-No powder handling or associated safety requirements (clean room, ventilation)
-Minimal waste, with all metal materials used going directly into production
-Ability to work with a wider range of metals, including refractory metals
-Small footprint, enabling operation in standard workshop conditions without special infrastructure
-Quick material changeover through our cartridge-based system
Which industries or applications are most likely to benefit from this technology, and what specific challenges does it address for them?
Based on customer discussions across many industries, we are focused on advancing applications in the following two main areas:
Special components for fusion energy:
Due to our unique ability to process refractory metals such as tungsten, we are advancing pilot projects to develop special components for fusion reactors. In particular, we are working on structural components with internal features, which until now have been impossible to achieve with additive manufacturing.
Single-layer depositions for electronics and special coatings:
Our system enables the placement of an already assembled component on the build bed and direct deposition onto it, without the need to heat the base part. For example, we can build antenna traces on drone structures, place a PCB and build EMI shielding, or place a cast component and add features to it.
Looking ahead, what are the next steps in the development process, and when do you expect your printers to be ready for customer testing?
We adhere to a lean operating principle and have a highly focused roadmap. Currently, we have working machines being used to advance customers’ pilot projects, demonstrating the capabilities and potential of our technology. Our next step is to productize this into a beta machine, which we are developing for some of those early customers.
We expect to have the first machines ready for public release within the next 12 to 18 months. Initially, we are focusing on customers who can provide valuable feedback as we refine the technology.
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