Enabling Design for Additive Manufacturing Through New Metallic Alloy Development

Advances in additive manufacturing (AM) of metallic engineering components are driving design for AM (DfAM), unlocking enhanced and new functionalities through unprecedented geometrical complexity and customization. However, the adoption of AM for critical engineering components is hindered by challenges in manufacturability, commonly referred to as printability or buildability, as most existing alloys were not designed for AM’s extreme thermo-kinetic conditions. Because of these hurdles, AM presents unique opportunities to develop tailored alloys optimized for both functionality and manufacturability. This integrated materials-manufacturing approach bridges technology and materials readiness gaps, enabling seamless transitions from computational alloy design to AM-fabricated components. We explore key examples in alloy design, gas atomization, laser powder bed fusion, and microstructural characterization, with case studies from Al-, Ni-, Fe-, and high-entropy alloys, specifically driven by user needs. Advancing alloy development specifically designed for AM is essential for its widespread adoption and continued innovation in engineering applications.