The Significance of Advancing Metal 3D Printing for the Manufacturing Industry – Interview with Freemelt CEO Daniel Gidlund

Freemelt was founded in 2017 by people with extensive knowledge, experience and success in E-PBF (Electron Powder Bed Fusion) 3D printing technology. Based in Sweden, the company offers customers a full range of products and services, including process development, application and product development, and seamless transition to industrial serial production. In an interview with 3Druck.com, CEO Daniel Gidlund shares his insight into the metal additive manufacturing industry.

One of the big challenges for additive manufacturing is the lack of awareness of the benefits and added value the technology brings to the manufacturing industry. Freemelt’s mission is to provide the industry with competence, knowledge, and awareness of E-PBF technology and to provide technology and solutions optimised for industrial serial production. The company aims to transform the 3D printing industry from a closed ecosystem with a focus on prototype printing to an open ecosystem with a focus on efficient industrial serial production. The goal is to become a productivity partner for its customers, enabling increased productivity and substantially reduced cost per manufactured part.

Freemelt offers a complete range of products and services to support customers from material process development in Freemelt^® ONE, application and product development in e^–MELT^®-iD, followed by a seamless transition to industrial serial production in e^–MELT^®-iM.

Interview with CEO Daniel Gidlund

In an interview with 3Druck.com, CEO Daniel Gidlund details the technological breakthroughs within the field of metal 3D printing as well as the company’s own progress and explains why he sees several crises as accelerating factors in an otherwise conservative industry.

In your opinion, what significance does metal 3D printing have for the manufacturing industry?

3D printing allows for the design and creation of complex and intricate metal parts with high precision, which is often challenging or impossible with traditional manufacturing methods. But 3D printing also brings key significance in enabling Industry 4.0, reducing waste, an optimised supply chain and to attract a younger generation of competence, as it’s a clean, silent, and digital manufacturing environment. 

Additive manufacturing has continuously developed in recent years. Which innovations or technological breakthroughs do you consider to be particularly important in the area of metal 3D printing?

I would say the most important innovations and technological breakthroughs in metal 3D printing are the development of specialised metal alloys for diverse applications and the enhancement of printing speed which makes industrial serial production more economically viable. Additionally, advancements in in-situ monitoring and quality control ensure higher precision, while innovations in post-processing techniques enhance mechanical properties and surface quality, meeting industry standards. These breakthroughs collectively contribute to the continuous evolution and broader adoption of metal 3D printing in various industrial applications.

If we zoom in on E-PBF where Freemelt is active, Freemelt has developed a couple of unique technological breakthroughs.

• E-PBF spot melting algorithms (Pixelmelt^®) for better microstructure control, better heat management, improved geometrical accuracy, and reduced need for support.
• Introduction of diode electron gun technology with consistent spot quality at beam power up to 6 kW. This is a true paradigm shift for high-productivity Electron Beam Powder Bed Fusion.
• Introduction of charge-free E-PBF preheating (ProHeat^®) that opens for a multitude of powder materials and powder size fractions that were previously impossible to process with E-PBF.
• Introduction of active cooling systems in E-PBF machines, which reduces the post-cooling time dramatically.
• Introduction of modular build units in E-PBF machines, enabling increased availability for production and improving turnaround times 

If I would highlight two applications that I personally feel a bit extra for, then I choose; Orthopaedic implants that can be manufactured in a material that makes the product lighter, and the structure of the product makes it integrate into the body in a better and more reliable way.

The other application is the tungsten components required in fusion reactors, where 3D printing has made it possible to improve the product structural stability and to increase the productivity of manufacturing the components. 

First Corona and the now high inflation pose major challenges for the entire industry. In your opinion, how do the multiple crises affect the additive manufacturing industry?

The occurrence of multiple crises can significantly impact industrial transformation in various ways. The metal manufacturing industry is a conservative industry that has evolved over thousands of years and where the industry has made substantial investments in technology and processes, which is why the sense of urgency for change is somewhat moderate. Therefore, the recent years of turmoil and crises such as the pandemic, the financial situation with inflation, and the current geopolitical situation are accelerating the interest in finding more innovative manufacturing opportunities.

This acceleration is mainly driven by large industries such as defence, energy, and semiconductors, and their increased interest in establishing local manufacturing to mitigate supply chain vulnerabilities.  

What impact do you think additive manufacturing will have on various industries and possibly society as a whole in the coming years?

Additive manufacturing is poised to have a profound impact on several industries and society in the coming years. The implications span from enhanced manufacturing capabilities to societal changes.  

As technology and the manufacturing industry continue to mature, I believe its impact on society will become more prominent, influencing how products are designed and how and where products are manufactured. – Shaping the future of a greener manufacturing industry and a sustainable society.

Here you can find further information on Freemelt and the E-BPF technology.