Similar to SLM but uses an electron beam in a vacuum. It offers higher build rates but generally results in a rougher surface finish.

Requires extensive post-processing (support removal, heat treatment) Rapid prototyping and on-demand manufacturing Limited library of printable "certified" alloys Improved energy efficiency and lower carbon footprint Potential for metallurgical defects like porosity Industry Expert Perspectives

Most metal AM processes involve selectively melting or joining metal feedstocks, typically in powder or wire form. The three most industrially relevant technologies include:

Feeds metal powder or wire directly into a heat source to build or repair components. This is frequently used for large-scale parts and remanufacturing applications. Materials and Metallurgy

Ti-6Al-4V is extensively used in aerospace for its strength-to-weight ratio. Nickel-based superalloys like Inconel 718 are favored for high-temperature energy and aerospace applications.

Modern AM can process a wide range of engineering materials, including steel, aluminum, titanium, nickel-based superalloys, and even precious metals. However, the rapid heating and cooling cycles inherent to these processes create unique microstructures that differ significantly from traditionally wrought parts.

The field is moving toward to enhance sustainability and further reduce costs. Current research priorities include the development of multi-material printing , real-time process monitoring, and sophisticated computational models to predict and prevent defects during the build process.