Additive Manufacturing

Additive manufacturing (AM), often colloquialized as 3D printing, has begun paving the way for a new generation of production capabilities in numerous industries. This innovative technology encompasses several distinct manufacturing techniques, including selective laser sintering (SLS), laser metal deposition (LMD), and rapid prototyping. Initially introduced as a game-changing innovation in polymer machining, AM is now used extensively to prototype intricate components with small geometries from some of the hardiest engineering materials available.

H.C. Starck Solutions has invested heavily into new AM technologies to accompany well-established refractory metal and alloy manufacturing capabilities. These two branches of the company coincide to enhance the range of products and services offered within each.

Methods

Since the introduction of AM, a large variety of process technologies have been developed of which no single method fits all applications. H.C. Starck Solutions works closely with its customers and partners to select the correct feedstock and method that will provide the most value to any given application.

Materials

H.C. Starck Solutions has powder and wire feedstock with tailored properties perfectly suited for AM. The company’s core competencies of W, Mo, Ta and Nb, in pure and alloyed forms, ensure materials with the highest quality and performance for our customers.

Markets

H.C. Starck Solutions’ refractory metal 3D printing solutions support our customers in all key end markets and enable them to benefit from the unique advantages of AM. Industries currently served include Medical, Aerospace, Industrial, Nuclear and Defense. H.C. Starck Solutions continuously broadens its portfolio and works on innovating and designing parts for applications in markets that have not previously utilized refractory metals.

Materials

H.C. Starck Solutions’ innovative powder and wire manufacturing technology coupled with our vertically integrated supply chain and metallurgical expertise ensures the highest quality materials for demanding applications and environments. Our advanced technological processes enable us to customize our refractory metal feedstock to precise requirements achieving outstanding material properties and optimum performance for additive manufacturing.

H.C. Starck Solutions’ powders are specifically designed to meet the demanding requirements of additive manufacturing technologies. Their properties exceed traditional production specifications and offer:

  • High purity
  • High bulk density
  • Spherical powder morphology
  • Exceptional flowability
  • Low oxygen
  • PSD optimized for specific printing methods

Our customized alloy powder product portfolio includes:

  • Tantalum Alloys: Ta-3W, Ta-10W
  • Molybdenum Alloys: TZM, Mo-La, Mo-Re
  • Tungsten Alloys: WHA, W-Re
  • Niobium Alloys: Nb C-103

We continuously develop new materials and methods and are ready to support your unique requests.

Methods

H.C. Starck Solutions provides the expertise to select the best material and method for each application, maximizing customer value by balancing cost vs dimensional accuracy and part performance.

3D Screen Printing

H.C. Starck Solutions’ 3D Screen Printing method for refractory metals uses a metal printing paste that is applied in vertical layers to create the required geometry. The technology is successfully utilized in producing complex grid structures.

Powder Bed Fusion

Probably the most well know AM method for metal parts is powder bed fusion. During this process, metal powders are spread in layers while laser or electron beam energy is used to melt and fuse the material together.

Binder Jet Printing

Binder Jet printing is a powder-bed method using polymer adhesives to bond the powders in layers. The method uses relatively thick printing layers and short build times to maximize the benefit to our customers.

Directed Energy Deposition

Directed energy deposition describes the technique of “directing” metal powder or wire at a specific location while a laser beam, electron beam or plasma arc melts and fuses the material together.

Markets 

H.C. Starck Solutions’ promise of highest quality and optimal performance make us an ideal partner for even the most critical application areas of AM refractory materials.

Radiation Imaging
Aerospace and Defense
Biomedical
Industrial

H.C. Starck Solutions’ diverse AM product portfolio includes 3D lead-free products for complex-geometry collimators and anti-scatter grids for CT scanners, SPECT and gamma cameras.

H.C. Starck Solutions provides high performance AM solutions for critical applications in Aerospace and Defense industries including propulsion, ballistics and warheads.

The reach of AM in end industries is expanding daily. H.C. Starck Solutions’ constant research into new applications and materials allows us to actively participate in the design of future solutions.

AM offers definite performance advantages for various medical applications in its ability to form porous structures to enhance bone osteointegration, tailor material properties to enhance implant design, and reduce overall part mass.

The corrosion resistance, durability, workability, and heat transfer properties of H.C. Starck Solutions materials make them ideal for challenging applications in the Chemical and Pharmaceutical industries. In addition, today’s demanding applications in heat treating, sintering, brazing, annealing, metalworking, and other thermal processing areas require innovative AM refractory metal product solutions.

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