Lithography-based Metal Manufacturing of Nickel Titanium

Lithography-based Metal Manufacturing (LMM) represents a novel additive manufacturing (AM) technique specifically engineered for producing complex, miniaturised metallic components that demand high precision and superior surface finish. The combination of high-resolution lithographic printing with scalable debinding and sintering processes has established a new pathway in metal manufacturing for sinterable metals. This approach enables expanded design freedom and advanced fabrication strategies, particularly in cases where conventional production techniques reach their limits. The technology distinguishes itself from other metal AM processes through its capability to generate fine features, intricate internal structures, and high-resolution surface details with high efficiency and reproducibility. These attributes make LMM particularly advantageous for applications in medical device engineering, micro-mechanical systems, and other domains where accuracy and miniaturisation are critical. This presentation will introduce the underlying principles of the LMM process and outline the complete process chain, beginning with feedstock formulation and proceeding through photopolymer-based printing, debinding, and sintering. In addition to describing the core process steps, MetShape’s material development activities, with an emphasis on nickel–titanium shape memory alloys, will be highlighted. Special attention will be given to the unique challenges and opportunities associated with processing nickel–titanium. Recent research and development illustrates how the LMM process can be tailored to yield functional NiTi components while preserving their characteristic material behaviour.