Mitsubishi Electric Corporation, Magnesium Research Center (MRC) of Kumamoto University, TOHO Kinzoku Co., Ltd., and the Japan Aerospace Exploration Agency (JAXA) worked together to develop the first high-precision additive manufacturing (AM) technology for magnesium alloys in a wire-laser metal 3D printer using the direct energy deposition (DED) method.
This technology will enable the production of lighter and stronger components for rockets, automobiles, and aircraft, leading to improved fuel efficiency and reduced production costs. For magnesium rocket components, this also means reduced production costs. In addition, the envisioned production processes based on a wire-laser metal 3D printer will be more energy efficient and generate fewer greenhouse gas emissions than conventional processes, delivering low-impact solutions for increased sustainability.
Since September 2022, the consortium members have been conducting joint research, called “Research on Laser Wire DED Method AM Process Technology Using Magnesium Alloy Wire,” under the framework of JAXA’s Innovative Future Space Transport System Research and Development Program, which is working to reduce the weight of rockets, thereby drastically cutting costs. In addition to rockets, the need for weight reduction in transportation products has recently increased due to the shift to electric vehicles and the growing demand for commercial aircraft.
Magnesium alloys are attracting attention in many fields. However, magnesium alloys are typically processed by die casting, making it difficult to create structures with hollow interiors. Also, the mainstream powder bed fusion (PBF) method for AM, which uses heat to melt metal powder, can lead to degradation through oxidation or dust explosions, posing a safety issue.
The new technology uses a magnesium alloy wire as an AM material and precise temperature control to prevent combustion. Further research and development targeting applications in various industrial fields will be conducted in parallel with Mitsubishi Electric’s work to commercialize the technology in a wire-laser DED metal 3D printer by around 2029.